An order processing system and a method of order processing

Abstract

An order processing system 100 comprising a first storage system 102 for a first set of goods held in goods transport means, and a second storage system 106 for a second set of goods. First storage system 102 has an automated storage system with a framework and a plurality of tile or platform units 116 arranged on a grided framework of columns and rows (Fig 6). Each of the plurality of tile units 116 are configured to support a goods transport means (508, Fig 8) holding a first set of goods and comprising a drive unit (Fig 9B) operable to move the goods transport means to an adjacent tile unit in a column direction or in a row direction. A first pick face 104 is formed at an edge of the grid at which the first set of goods are accessible for retrieval, and a control system operable to individually control the tile units to move the goods transport means around the grid and into, and out of, first pick face 104. Second storage system 106 has a second pick face 108 at which the second set of goods are accessible for retrieval. First storage system 102 and second storage system 106 are arranged such that first pick face 104 is adjacent to second pick face 108. Order processing system 100 further comprises a pick area 110 first and second pick faces 104, 108 and pick area 110 comprises a support 112 for receiving goods retrieved from first pick face 104 and second pick face 108.

Description

[0001] This invention relates to an order processing system for processing goods, for example for storing goods and retrieving goods for onward conveyance or delivery. This invention also relates to a method of order processing. BACKGROUND

[0002] Order processing systems are used to store different goods that are then retrieved, either manually or in an automated manner, and packed for order fulfilment. Such order processing systems are common for fulfilling online orders, for example, in groceries and consumer goods.

[0003] Order processing systems typically consist of a number of storage locations formed in storage racks (e.g., shelving units) that permit an operator or robot to access each storage location for depositing or retrieving goods. In each storage location goods may be stored in totes, cages, or pallets. In some examples, the storage racks are separated by fixed or moveable aisles. In other examples order processing systems may use shuttle robots or conveyors to move goods between different locations. Depending on the goods, they may be handled directly or placed in containers such as totes for transport and storage.

[0004] Automated order processing systems provide advantages for systems that store a large number of different types of goods, where manual retrieval would be inefficient. However, storing a large number of different goods may cause difficulties where some goods have a much higher retrieval frequency than others. Manual retrieval systems are effective in systems that store a relatively few number of different types of goods, each with a high retrieval frequency, because the goods can be presented in a relatively small area for efficient manual picking. SUMMARY OF THE INVENTION

[0005] According to a first aspect of the invention, there is provided an order processing system comprising: a first storage system for a first set of goods held in goods transport means, the first storage system comprising an automated storage system having: a framework, a plurality of tile units arranged on the framework in a grid of columns and rows, wherein each of the plurality of tile units is configured to support one of the goods transport means holding the first set of goods and comprises a drive unit operable to move the goods transport means to an adjacent tile unit in a column direction or in a row direction, a first pick face formed at an edge of the grid at which the first set of goods are accessible for retrieval, and a control system operable to individually control the tile units to move the goods transport means around the grid and into, and out of, the first pick face; wherein the order processing system further comprises a second storage system for a second set of goods and having a second pick face at which the second set of goods are accessible for retrieval, wherein the first storage system and the second storage system are arranged such that the first pick face is adjacent to the second pick face, and wherein the order processing system further comprises a pick area between the first pick face and the second pick face, the pick area comprising a support for receiving goods retrieved from the first pick face and the second pick face.

[0006] Advantageously, providing two different storage systems, each with its own pick face arranged adjacently in a pick area, allows an operator or a robot to retrieve goods from both storage systems. As the first storage system is an automated storage system it can advantageously be used to store a wide variety of goods that can be stored, sorted, and presented at the first pick face in an appropriate order and timing to fulfil orders.

[0007] In examples, the support is moveable along the pick area between the first pick face and the second pick face. In examples, the support is adapted to hold receiving containers, in particular a plurality of receiving containers.

[0008] In examples, the support comprises a trolley adapted to receive goods. The trolley may be adapted to hold receiving containers, in particular a plurality of receiving containers. The trolley may be manually moveable, or the order processing system may further comprise a trolley drive system arranged to move the trolley.

[0009] In other examples the order processing system may comprise a support drive system that moves the support along the pick area. The support drive system extends at least partially, preferably fully, along the pick area.

[0010] In examples, the support drive system may comprise a plurality of tile units arranged to form a conveyor. The conveyer may have one or more rows, for example two rows, allowing multiple supports to be arranged on the support drive system and moved past each other. In examples, the tile units forming the conveyor are each configured to support a support and each comprises a drive unit operable to move the support to an adjacent tile unit. Where the conveyor comprises more than one row of tile units, the drive unit may be operable to move the support to an adjacent tile unit in a row direction or in a column direction. In such examples the support may comprise a container, a trolley, a pallet, a cage, or racking, for example shelving for holding goods or containers. Accordingly, the support drive system, in particular the drive units of the tile units, can be operated to move the support along the pick area. In examples, the support drive system may be connected with a further conveyor (which may comprise further tile units) for conveying the support(s) to a destination away from the pick face (e.g., a loading bay), and for returning the support(s) to the pick face.

[0011] Advantageously, moving the support through the pick area, in particular along the first pick face, allows an operator (or robot) to increase the rate at which goods are retrieved because different goods can be presented along the first pick face and changed over when the support is at a different location along the first pick face. Accordingly, the retrieval efficiency of the automated storage system is improved by having a support that moves along the first pick face because an operator or robot does not have to wait for the automated storage system to change which goods transport means is presented at the first pick face - instead they can move to a different part of the first pick face while the goods transport means are changed over.

[0012] In examples, the support may be configured to hold a plurality of receiving containers, for example 2, 3, 4, 5, 6 or more receiving containers. Advantageously, multiple of a particular type of goods retrieved from the first pick face or the second pick face may be loaded into more than one of the receiving containers on the support at the same time. This so called ‘batch picking’ can greatly increase the efficiency and throughput of the goods retrieval operation because items of goods for multiple orders can be retrieved in a single picking operation.

[0013] According to a second aspect of the invention, there is provided an order processing system comprising: an automated storage system comprising: a framework, a plurality of tile units arranged on the framework in a grid of columns and rows, wherein each of the plurality of tile units is configured to support a goods transport means holding goods and comprises a drive unit operable to move the goods transport means to an adjacent tile unit in a column direction or in a row direction, a pick face formed at an edge of the grid at which the goods are accessible for retrieval, and a control system operable to individually control the plurality of tile units to move the goods transport means around the grid and into, and out of, the pick face; and a support for receiving goods retrieved from the goods transport means at the pick face, wherein the support is disposed adjacent to the pick face and is moveable along the pick face.

[0014] The support may be adapted to hold receiving containers, in particular a plurality of receiving containers. In examples, the support may be configured to hold 2, 3, 4, 5, 6 or more receiving containers. Advantageously, multiple of a particular type of goods retrieved from the pick face may be loaded into more than one of the receiving containers on the support at the same time. This so called ‘batch picking’ can greatly increase the efficiency and throughput of the goods retrieval operation because items of goods for multiple orders can be retrieved in a single picking operation.

[0015] In examples, the support comprises a trolley adapted to receive goods. The trolley may be manually moveable, or the order processing system may further comprise a trolley drive system arranged to move the trolley.

[0016] In other examples the order processing system may comprise a support drive system that moves the support along the pick area. The support drive system extends at least partially, preferably fully, along the pick face.

[0017] In examples, the support drive system may comprise a plurality of tile units arranged to form a conveyor. The conveyer may have one or more rows, for example two rows, allowing multiple supports to be arranged on the support drive system and moved past each other. In examples, the tile units forming the conveyor are each configured to support a support and each comprises a drive unit operable to move the support to an adjacent tile unit. Where the conveyor comprises more than one row of tile units, the drive unit may be operable to move the support to an adjacent tile unit in a row direction or in a column direction. In such examples the support may comprise a container, a trolley, a pallet, a cage, or racking, for example shelving for holding goods or containers. Accordingly, the support drive system, in particular the drive units of the tile units, can be operated to move the support along the pick face. In examples, the support drive system may be connected with a further conveyor (which may comprise further tile units) for conveying the support(s) to a destination away from the pick face (e.g., a loading bay), and for returning the support(s) to the pick face.

[0018] Advantageously, moving the support along the pick face allows an operator (or robot) to increase the rate at which goods are retrieved because different goods can be presented along the pick face and changed over when the support is at a different location along the pick face. Accordingly, the retrieval efficiency of the automated storage system is improved by having a support that moves along the pick face because an operator or robot does not have to wait for the automated storage system to change which goods transport means is presented at the pick face - instead they can move to a different part of the pick face while the goods transport means are changed over.

[0019] In examples, the pick face is a first pick face. The order processing system may further comprise a second storage system having a second pick face arranged adjacent to the first pick face and defining a pick area between the first pick face and the second pick face. The support may be moveable along the pick area. The automated storage system may hold a first set of goods and the second storage system may hold a second set of goods.

[0020] In examples, the second pick face is arranged on a different side of the pick area to the first pick face, for example on an opposite side. In examples, the first pick face and the second pick face are parallel and spaced apart from each other. In other examples, the first pick face and the second pick face are angled with respect to each other, for example up to 90 degrees. In examples, the first pick face and the second pick face are both straight, or one or both of them could be curved, for example one may wrap around the other in a U-shape.

[0021] In examples, the second storage system comprises a racking system. In examples, the racking system comprises a plurality of lanes for receiving goods transport means holding the second set of goods. In examples, the goods transport means in each lane of the racking system hold the same goods so that particular goods are consistently presented at the same location on the second pick face. In examples, the racking system comprises a flow racking system, and the goods transport means are urged along each lane towards the second pick face. In other examples, the racking system comprises roller racking, or shelving on which trays or other containers are placed.

[0022] In examples, the second storage system holds a plurality of goods transport means, in particular containers or pallets or cages or trolleys or roll-pallets or roll-cages. The goods transport means may be received directly on the floor, and may include wheels or be mounted on dollies for moving around. Guides or rails may be provided to guide the goods transport means in rows within the second storage system. In some examples, the goods transport means may be held on roller conveyors or the like within the second storage system. The goods transport means of the second storage system may be large goods transport means, in particular larger than the goods transport means of the first storage system, holding more items of goods than the goods transport means of the first storage system. In this way, the second storage system can provide storage and retrieval for a smaller number of different goods than the first storage system, and at a higher frequency / volume.

[0023] In examples, the second storage system comprises an automated storage system for the second set of goods held in goods transport means, the automated storage system comprising: a framework, a plurality of tile units arranged on the framework in a grid of columns and rows, wherein each of the plurality of tile units is configured to support one of the goods transport means holding the second set of goods and comprises a drive unit operable to move the goods transport means to an adjacent tile unit in a column direction or in a row direction, a second pick face formed at an edge of the grid at which the second set of goods are accessible for retrieval, and a control system operable to individually control the tile units to move goods transport means around the grid and into, and out of, the second pick face.

[0024] In examples, the automated storage system holds a first set of goods transport means and the second storage system holds a second set of goods transport means. The first set of goods transport means may be different to the second set of goods transport means. For example, first set of goods transport means may be a different type or size of goods transport means to the second set of goods transport means. For example, one may comprise trays or trolleys or pallets or cages, and the other storage containers. In other examples, the first set of goods transport means and the first set of goods transport means may be the same type and / or size of goods transport means but do not mix. Specifically, in examples the first set of goods transport means does not mix with the second set of goods transport means. That is, the first set of goods transport means does not enter the second storage system, and the second set of goods transport means does not enter the first storage system.

[0025] In examples, the first set of goods have a first expected retrieval frequency, and the second set of goods have a second expected retrieval frequency. The first expected retrieval frequency may be different to the second expected retrieval frequency. For example, the second expected retrieval frequency may be higher than the first expected retrieval frequency.

[0026] Advantageously, the second storage system can be used for high frequency goods that are more often picked for order fulfilment and which include fewer different types of goods than the first set of goods. The second storage system can be configured to store the second set of goods in such a way that they are reliably presented at the second pick face, possibly always in the same location, without the need to call those goods from within a storage system where they are mixed with lower frequency goods. At the same time, the first storage system provides space-efficient storage for the first set of goods with a lower retrieval frequency, but the automated movement of the goods transport means in the first storage system allows those goods to the efficiently moved and presented at the first pick face. Therefore, the combination of the first storage system and the second storage system greatly improves the overall retrieval efficiency of the order processing system by separating the goods into different storage systems according to their expected retrieval frequency.

[0027] In examples, the order processing system further comprises a third storage system for storing a third set of goods having a third expected retrieval frequency. The third expected retrieval frequency may be lower than the first expected retrieval frequency and the second expected retrieval frequency. Advantageously, by providing a third storage system for the third set of goods these third set of goods are not occupying space within the first storage system, so the first storage system can be smaller (fewer storage locations) and can operate more efficiently when moving goods transport means to the first pick face.

[0028] In examples, the third storage system is arranged at one end of the pick area, or away from the pick area, for example in a different room or even a different building. In examples, the third storage system does not have a pick face present in the pick area. In examples, the order processing system may further comprise a transfer system for transferring goods from the third storage system to the pick area or to the automated storage system. The transfer system may be manual, including trolleys or containers that are loaded in the third storage system and then moved to the pick area or the automated storage system. Or the transfer system may include a conveyor or shuttle robot(s). The goods transferred from the third storage system may be provided directly to the pick area for retrieval and moving to the support, or they may be fed into the automated storage system (e.g., the first storage system) and moved to the first pick face at the appropriate time to fulfil an order.

[0029] In examples, the first pick face is spaced from the second pick face by no more than 5 metres, for example less than 5 metres, for example less than 3 metres, for example less than 2 metres. Advantageous, an operator or robot can thereby easily reach both the first pick face and the second pick face and their pick rate can be improved.

[0030] In examples, at least one of the or each pick face (specifically the first pick face and / or the second pick face and / or the pick face) comprises a row of tile units. The row of tile units can receive goods transport means from the grid and present them at the pick face for retrieval of goods. In other examples, at least one of the or each automated storage system comprises a conveyor extending at least partially along the pick face. The conveyor may receive goods transport means from the grid and present them for retrieval of goods. The conveyor may move empty or unneeded goods transport means back into the grid or elsewhere.

[0031] In examples, at least one of the or each framework comprises more than one vertically-stacked level, each level having a plurality of tile units arranged in rows and columns and forming a grid of tile units. In examples, the order processing system may further comprise at least one lift for moving goods transport means between levels. The lift(s) may be arranged at an edge of the grid, or within the grid (away from the edge).

[0032] In examples, at least one of the or each pick face may comprise a first edge row of tile units formed at an edge of a first level, and a space above the first edge row to allow retrieval of goods from goods transport means on the first edge row. Advantageously, the space allows an operator or robot to access the goods transport means and remove goods from the goods transport means.

[0033] In examples, at least one of the or each pick face further comprises a second edge row of tile units formed at an edge of a second level. Advantageously, the pick face may include multiple levels from which goods can be retrieved, allowing for a greater number of goods transport means to be presented at the pick face and improving the pick rate.

[0034] In examples, at least one of the or each automated storage system further comprises an intermediate level between the first level and the second level. The first level may be below the intermediate level. The intermediate level may comprise an intermediate edge row of tile units offset from the first edge row to define the space above the first edge row. The space above the first edge row of tile units allows an operator or robot to access the goods transport means and remove goods from the goods transport means. In this example, the intermediate level does not form a part of the pick face, so is used for storage of goods transport means that can then be moved to a different level (e.g., by a lift) to be moved into the pick face.

[0035] In examples, each drive unit comprises a drive wheel operable to engage a goods transport means supported on the tile unit and to move the goods transport means to an adjacent tile unit. In examples, each drive wheel is swivelable through 90 degrees such that the drive wheel can move the goods transport means in a row direction or in a column direction. In examples, each drive unit comprises a plurality of drive wheels, for example two, three or four drive wheels. In examples, the or each drive wheel is fixed in a vertical direction.

[0036] In examples, a plurality of the tile units of at least one of the or each automated storage system define a storage area for storing goods transport means. The storage area may be separate to the pick face. That is, the pick face is defined at one edge of the grid (e.g., by some of the plurality of tile units along the edge of the grid), and at least some tile units that are not accessible at the pick face are used for storage. Some tile units may be used for queuing or collating goods transport means before they are moved into the pick face. Any tile unit may be used for storing, queuing, or collating.

[0037] In examples, the goods transport means comprises a storage container. In examples, the goods transport means comprises a skid plate. In examples, the goods transport means comprises a storage container supported on a skid plate, which is supported on a tile unit. The storage container may be a storage tote, a box, a tray, a trolley, a cage, a pallet, and may include a dolly (tray with wheels).

[0038] According to a further aspect of the invention there is also provided a method of order processing. The method comprises operating any of the order processing systems described above.

[0039] According to a further aspect of the invention there is also provided a method of order processing, the method comprising: storing a first set of goods in a first storage system, the first storage system being an automated storage system adapted to store the first set of goods in goods transport means and operable to move the goods transport means to a first pick face of the automated storage system for retrieval of goods therefrom, storing a second set of goods in a second storage system, the second storage system having a second pick face for retrieval of goods therefrom, wherein the second pick face is adjacent to the first pick face in a pick area, and retrieving goods from the first pick face and the second pick face for order fulfilment, wherein the first set of goods has a lower expected retrieval frequency than the second set of goods.

[0040] In examples, the second set of goods comprises fewer different types of goods than the first set of goods.

[0041] In examples, the method comprises retrieving multiple of a type of goods from the first pick face or the second pick face and depositing the retrieved goods in a plurality of retrieval receiving containers.

[0042] The first storage system and the second storage system may be as described above in relation to other examples.

[0043] According to a further aspect of the invention there is also provided a method of order processing, the method comprising: storing goods in an automated storage system having a pick face from which goods can be retrieved from a plurality of locations, for example from a plurality of tile units arranged in the pick face, presenting the goods at the pick face, and moving a support along the pick face while retrieving goods from the automated storage system.

[0044] Advantageously, the goods presented at the pick face can be changed over while the support is at a different location on the pick face, and goods can be presented at the pick face with the appropriate order, timing, and location for improved retrieval for order fulfilment.

[0045] In examples, the method comprises retrieving multiple of a type of goods from the pick face in a batch, and distributing the retrieved items into a plurality of receiving containers. Advantageously, such ‘batch-picking’ can greatly increase the efficiency and throughput of the goods retrieval operation because items of goods for multiple orders can be retrieved in a single picking operation.

[0046] The automated storage system may be the first storage system as described above in relation to other examples. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0047] Examples of the invention are described, by way of example only, with reference to accompanying drawings, in which:

[0048] FIG. 1 illustrates an example order processing system having a first storage system and a second storage system.

[0049] FIG. 2 illustrates an example order processing system having a first storage system, a second storage system and a third storage system.

[0050] FIG. 3 illustrates an example order processing system having a first storage system and a second storage system.

[0051] FIG. 4 illustrates an example order processing system having a first storage system, a second storage system and a third storage system.

[0052] FIG. 5 illustrates an example automated storage system having multiple layers.

[0053] FIG. 6 illustrates a further example automated storage system having multiple layers.

[0054] FIG. 7 illustrates an example automated storage system having a single layer.

[0055] FIG. 8 illustrates a part of the automated storage system of FIG. 5, or FIG. 6 or FIG. 7.

[0056] FIG. 9A illustrates an example tile unit of the automated storage system of FIG. 5 or FIG. 6 or FIG. 7.

[0057] FIG. 9B illustrates the tile unit of FIG. 9A with a top removed.

[0058] FIG. 9C illustrates a swivel mechanism of the tile unit of FIG. 9A and FIG. 9B.

[0059] FIG. 10 illustrates a further example tile unit of the automated storage system of FIG. 5 or FIG. 6 or FIG. 7.

[0060] FIG. 11 illustrates different goods transport means of the automated storage system of FIG. 5 or FIG. 6 or FIG. 7.

[0061] FIG. 12 illustrates the underside of a goods transport means of the automated storage system of FIG. 5 or FIG. 6 or FIG. 7. DETAILED DESCRIPTION

[0062] FIG. 1 shows an order processing system 100 for processing goods, for example sorting and collating goods for packaging and / or delivery. As explained further below, within the order processing system 100 the goods are stored in goods transport means. In the examples described below the goods transport means are storage containers. The storage containers may be supported on skid plates that are moved around the order processing system 100. However, in other examples the goods may be received directly on the skid plates, or the skid plates could be omitted and storage containers can be supported on the tile units. Each goods transport means (e.g., storage container) may hold one or more of the same goods, or a mix of different goods. In various examples the goods may be groceries, clothing, retail goods and the like. The storage containers may be, for example storage totes, storage boxes, cages, trays, bags, pallets. The storage containers may have a standardised size.

[0063] The order processing system 100 includes a first storage system 102 and a second storage system 106. The first storage system 102 has a first pick face 104 and the second storage system 106 has a second pick face 108. In the example shown the first pick face 104 faces the second pick face 108. Specifically, the first pick face 104 and the second pick face 108 are both straight and arranged opposite one another and spaced from each other. A pick area 110 is defined between the first pick face 104 and the second pick face 108. Within the pick area 110 an operator (not illustrated) can retrieve goods from the first storage system 102 and from the second storage system 106 at the first pick face 104 and the second pick face 108, respectively.

[0064] As illustrated, a support may be provided in the pick area 110. In this example, the support is a trolley 112 that is moveable along the pick area 110, between the first pick face 104 and the second pick face 108. In examples, the trolley 112 may be manually moveable, or may be provided on a trolley drive system (e.g., a conveyor) that moves the trolley 112 between the first pick face 104 and the second pick face 108. The trolley 112 may have shelves or pigeonholes or the like to receive goods retrieved from the first storage system 102 and the second storage system 106. In some examples the trolley 112 holds one or more, preferably a plurality, of receiving containers into which retrieved goods are deposited. Once the appropriate goods have been deposited into the trolley 112, the trolley 112 can be moved to an unloading station, for example where the receiving containers can be loaded into delivery vehicles or onto an onward conveyor. In some examples there may be more than one trolley 112 in the pick area 110.

[0065] In particular examples, the trolley 112 holds a plurality of receiving containers and goods can be ‘batch-picked’ and distributed to multiple receiving containers at the same time. That is, multiple of a particular type of goods can be retrieved from the first pick face 104 or second pick face 108 and distributed into multiple receiving containers.

[0066] In other examples, the support may alternatively comprise a container, a pallet, a cage, or racking, for example shelving for holding goods or containers. A support drive system may be provided to move the support between the first pick face 104 and the second pick face 108. The support drive system may be a conveyor formed of a plurality of tile units, such as the tile units described in detail hereinafter.

[0067] In some examples one or more operators work in the pick area 110 to retrieve goods from the first pick face 104 and the second pick face 108 and deposit them in the trolley 112. In other examples, one or more robots (e.g., pick and place robots) may be provided in the pick area 110 to retrieve goods from the first pick face 104 and the second pick face 108 and deposit them in the trolley 112. In some examples both human operators and robots may be present in the pick area 110 and working in tandem.

[0068] In the illustrated example the first storage system 102 comprises an automated storage system 500, which is described in more detail below with reference to FIGS. 5 to 11. The automated storage system 500 comprises a plurality of tile units 116 arranged in a grid having rows and columns.

[0069] Each of the tile units 116 can support a goods transport means, in particular a storage container and / or skid plate.

[0070] As explained in more detail below, each tile unit 116 also has a drive unit for moving the storage containers to an adjacent tile unit 116 in a row direction or in a column direction. A row or column of tile units 116 may form the first pick face 104, and the tile units 116 can be operated to move storage containers around the grid and into, and out of, the first pick face 104. Empty storage containers can be moved to an output, which may be a particular tile unit or side of the first storage system 102, and (re-)loaded storage containers can be added to the first storage system 102. In this way, the grid of tile units 116 can be used to store storage containers and to move storage containers into the first pick face 104 for retrieval of goods into the pick area 110.

[0071] As explained further below, the first storage system 102 may comprise one level (tier) or a plurality of levels. At least some of the levels, for example only some of the levels or all of the levels, may extend to the first pick face 104 so that goods can be retrieved from storage containers on those levels. The levels that extend to the first pick face 104 are preferably arranged at a height and in a position suitable for an operator to retrieve goods.

[0072] In various examples the second storage system 106 may comprise a racking system (e.g., roller racking, flow racking), a shelving system, a plurality of pallets (e.g., on dollies or roller conveyors), or a series of trolleys or cages that may themselves be received on dollies or directly on the floor (with optional guides on the floor). The second storage system 106 is not an automated storage system.

[0073] In the illustrated example the second storage system 106 comprises a flow racking system. The flow racking system has an array of lanes 114 in which storage containers are stored. The storage containers are urged along the lanes 114 towards the second pick face 108, for example by actuators or by the lanes 114 being inclined downwards towards the second pick face 108. Each lane 114 may hold a plurality of storage containers, and the storage containers of each lane 114 may all hold the same goods. Empty storage containers can be removed from the second pick face 108 to allow the storage container behind to move into the second pick face 108. (Re-)loaded storage containers can be added to the second storage system 106 at the opposite ends of the lanes 114. In examples, the second storage system 106 has at least one level (tier) of racking, but preferably comprises a plurality of levels arranged such that storage containers on each level can be reached by an operator in the pick area 110.

[0074] In other examples, pallets, trolleys, or cages (optionally on roller conveyors or dollies) may be moved into and out of the second storage system 106, or trays of goods may be moved into and out of shelves in the second storage system 106. Each trolley, pallet, cage, or tray may hold a plurality of the same type of goods. Trolleys, pallets, or cages (optionally on roller conveyors or dollies) may be supported on a framework or directly on the floor, optionally with some floor-mounted rails or guides to arrange them in rows.

[0075] In examples, the second storage system 106 may hold goods that have a higher expected retrieval frequency than goods held in the first storage system 102. The expected retrieval frequency may be based on historic and / or forecast order data. For example, in groceries, goods such as milk and cucumbers may have a higher expected retrieval frequency than other goods. Advantageously, the second storage system 106 provides consistent retrieval availability for goods with a high expected retrieval frequency to ensure that an operator in the pick area 110 can pick those goods from the second pick face 108 when needed. Meanwhile, the first storage system 102 provides efficient storage of goods with a lower expected retrieval frequency and can present those goods at the first pick face 104 when needed and in an appropriate location along the first pick face 104. The number of different goods types may be lower in the second storage system 106 than in the first storage system 102.

[0076] The example order processing system 200 of FIG. 2 is similar to that of FIG. 1 except that it additionally includes a third storage system 202. The third storage system 202 is located away from the pick area 110 and may be used to store goods with a lower expected retrieval frequency than the goods in the first storage system 102 or the second storage system 106. The number of different goods types stored in the third storage system 202 may be higher than in the second storage system 106 and the first storage system 102. The goods stored in the third storage system 202 may be needed for relatively few orders, so can be provided ad-hoc rather than using up storage capacity of the first storage system 102.

[0077] A transfer system 204, for example a conveyor or manual trolley system, may be provided to transfer goods (optionally held in storage containers) to the pick area 110 for loading onto the trolley 112, and / or from the third storage system 202 into the first storage system 102, after which the goods may be moved to the first pick face 104 for retrieval as described above. Goods may be collated on the transfer system 204. For example, different goods may be manually loaded from the third storage system 202 into a container or trolley, which is then transferred to the pick area 110 or first storage system 102.

[0078] Advantageously, storing goods with a low expected retrieval frequency outside of the first storage system 102 may reduce the overall size of the first storage system 102 (i.e., the number of tile units 116) and / or may improve the latency of the first storage system 102 (i.e., reduce the time it takes for a particular storage container held in the first storage system 102 to be presented at the first pick face 104 after being ‘called’).

[0079] The example order processing system 300 of FIG. 3 is similar to that of FIG. 1 except that the second storage system 106 comprises an automated storage system. In particular, in this example both the first storage system 102 and the second storage system 106 comprise an automated storage system 500, 600, 700, which is described in more detail below with reference to FIGS. 5 to 11. Each of the automated storage systems comprises a plurality of tile units 116 arranged in a grid having rows and columns. The tile units 116 can each support a storage container and have a drive unit for moving the storage containers to adjacent tile units 116 in a row direction or in a column direction. A row or column of tile units 116 may form the first pick face 104 and the second pick face 108, and the tile units 116 can be operated to move storage containers around the grid and into, and out of, the first pick face 104 and the second pick face 108. Empty storage containers can be moved to an output, which may be a particular tile unit or side of the first storage system 102 and second storage system 106, and (re-)loaded storage containers can be added to the first storage system 102 and the second storage system 106. In this way, the grid of tile units 116 can be used to store storage containers and to move storage containers into the first pick face 104 and the second pick face 108 for retrieval of goods into the pick area 110.

[0080] In examples, the second storage system 106 may hold goods have a higher expected retrieval frequency than goods held in the first storage system 102. The expected retrieval frequency may be based on historic and / or forecast order data. For example, in groceries, goods such as milk and cucumbers may have a higher expected retrieval frequency than other goods. Advantageously, the second storage system 106 can be operated differently to the first storage system 102 such that the goods with a higher expected retrieval frequency are reliably available for retrieval from the second pick face 108 to ensure that an operator in the pick area 110 can pick those goods from the second pick face 108. Providing a limited number of types of goods within the second storage system 106 ensures that the goods with a high expected retrieval frequency can be quickly presented for retrieval from the second pick face 108. Meanwhile, the first storage system 102 provides efficient storage of goods with a lower expected retrieval frequency and can present those goods at the first pick face 104 when needed and in an appropriate location along the first pick face 104. The number of different goods types may be lower in the second storage system 106 than in the first storage system 102.

[0081] The example order processing system 400 of FIG. 4 is similar to that of FIG. 3 except that it additionally includes a third storage system 402. The third storage system 402 is located away from the pick area 110 and may be used to store goods with a lower expected retrieval frequency than the goods in the first storage system 102 or the second storage system 106. Such goods are needed for relatively few orders, so can be provided ad-hoc rather than using up storage capacity of the first storage system 102 and the second storage system 106.

[0082] A transfer system 404, for example a conveyor or manual trolley system, may be provided to transfer goods (optionally held in storage containers) to the pick area 110 for loading onto the trolley 112, and / or from the third storage system 402 into the first storage system 102, after which the goods may be moved to the first pick face 104 for retrieval as described above. Goods may be collated on the transfer system 404. For example, different goods may be manually loaded from the third storage system 402 into a container or trolley, which is then transferred to the pick area 110 or first storage system 102.

[0083] Advantageously, storing goods with a low expected retrieval frequency outside of the first storage system 102 and the second storage system 106 may reduce the overall size of the first storage system 102 (i.e., the number of tile units 116) and / or may improve the latency of the first storage system 102 (i.e., reduce the time it takes for a particular storage container held in the first storage system 102 to be presented at the first pick face 104 after being ‘called’).

[0084] In the examples of FIG. 1 to FIG. 4 the first pick face 104 and the second pick face 108 may be arranged opposite to each other and extend parallel to each other, as illustrated. In various examples the first pick face 104 and the second pick face 108 are adjacent to one another and the pick area 110 is arranged between them. The first pick face 104 and the second pick face 108 may be formed along straight lines, as illustrated, or they may be curved, and thus the pick area 110 may be curved. In some examples, the first pick face 104 may wrap around the second pick face 108, or vice versa, for example in a U-shape. In some examples, the first pick face 104 and the second pick face 108 may be non-parallel, for example arranged at up to 90 degrees from one another.

[0085] Accordingly, the first pick face 104, the second pick face 108, and the pick area 110 can be configured according to various factors including a desired number of pick locations, a number of supports (trolleys 112) or operators, or the physical constraints of the installation location (e.g., space, positions of the first storage system 102 and first pick face 104, and the position of any vehicle bays or existing conveyors).

[0086] As explained above, the second storage system 106 may hold goods with a relatively high expected retrieval frequency, and the first pick face 104 may hold goods with a lower expected retrieval frequency than the goods in the second storage system 106. The third storage system 202, 402, where provided, may hold goods with a lower expected retrieval frequency than the first storage system 102 or the second storage system 106.

[0087] In various examples, and depending on the nature of the goods being stored and processed in the order processing system 100, the second storage system 106 may hold goods with the top 20% or less, or the top 10% or less, of expected retrieval frequency (i.e., the 20% or 10% of goods with the highest expected retrieval frequency). Such goods may account for up to a half of all individually called goods, and the second storage system 106 can ensure that such goods are reliably available for retrieval at the pick area 110. The first pick face 104 may hold goods covering the next 50% based on expected retrieval frequency, and the third storage system 202, 402 may hold the remaining goods. Such an arrangement advantageously improves throughput of the order processing system 100 by ensuring that the goods with the highest expected retrieval frequency are available, providing an automated storage system with low latency for goods with a lower expected retrieval frequency, and storing other goods (with an even lower expected retrieval frequency) in a different area so as to maintain the latency of the automated storage system.

[0088] FIG. 5 shows an automated storage system 500, which may be used as the first storage system 102 and / or the second storage system 106 as described with reference to FIG. 1 to FIG. 4. As illustrated, the automated storage system 500 comprises a framework 502 on which a plurality of tile units 504 are mounted. The framework 502 may be provided within a warehouse or other location and may be formed of columns and beams attached together to define a plurality of layers (tiers) as shown. The framework 502 may include legs, as illustrated, to raise the plurality of tile units 504 off the floor, or the plurality of tile units 504 may be arranged a floor level.

[0089] The tile units 504 are arranged on the framework 502 in a grid 506 having rows and columns. In this example one side of the grid 506 forms a pick face 510, which may be the first pick face 104 and / or second pick face 108 as described above. For the purpose of this description, in these examples the rows extend parallel to the pick face 510 and the columns perpendicularly to the rows.

[0090] The tile units 504 that form the grid 506 are arranged side-by-side in the rows and columns so that no gap, or a small gap, is provided between adjacent tile units 504. As described below, a storage container 508 can be supported on each tile unit 504 and driven from one tile unit 504 to an adjacent tile unit 504 in a row direction or in a column direction.

[0091] In the illustrated example the automated storage system 500 comprises a plurality of levels, in this example two levels - a top level 514 and a bottom level 512. In other examples, intermediate levels may be provided between the top level 514 and the bottom level 512, for example one, two, three, four or more intermediate levels. The levels are stacked on top of each other and defined by the framework 502. In this example the top level 514 and the bottom level 512 are aligned but m some examples, depending on the particular installation, they need not be aligned. One or more lifts (not illustrated) may be provided for moving storage containers 508 between the top level 514 and the bottom level 512 (and any intermediate level). The lifts may include a tile unit 504 that can be moved vertically into alignment with different levels and can therefore be operated to move a storage container 508 between the levels.

[0092] As shown in FIG. 5, the top level 514 and the bottom level 512 each include an edge row. As illustrated, the bottom level 512 includes a bottom edge row 516, the top level 514 includes a top edge row 518. In other examples, the or each intermediate level also includes an intermediate edge row. At least some part of at least one of the edge rows forms the pick face 510.

[0093] In this example the edge rows 516, 518 are at least partially vertically aligned, one above another, to form a vertical pick face 510. Where the edge rows 516, 518 are vertically aligned an operator to access storage containers 508 on the top edge row 518 but not the bottom edge row 516. In this example, the top edge row 518 only extends partially across the pick face 510 and at one end the top edge row 518 is omitted. Accordingly, at this end (where the bottom edge row 516 and top edge row 518 are offset and not vertically aligned) an operator can access the storage containers 508 on the bottom edge row 516. It will be appreciated that various arrangements may be provided for accessing the storage containers 508 at the pick face 510.

[0094] In other examples, storage containers 508 on an intermediate level or on the bottom level 512 may be accessible through spaces created by omitted parts of an end rows of tile units 504 in the level above, or by spacing the levels vertically to provide space above the storage containers 508.

[0095] In other examples, one or more of the edge rows may be fully or partially omitted such that the edge row below the omitted edge row has more space above the storage containers 508 for retrieval of goods.

[0096] FIG. 6 shows a further example automated storage system 600, which may be used as the first storage system 102 and / or the second storage system 106 as described with reference to FIG. 1 to FIG. 4. As illustrated, the automated storage system 600 comprises a framework 602 on which a plurality of tile units 604 are mounted. The framework 602 may be provided within a warehouse or other location and may be formed of columns and beams attached together to define a plurality of layers (tiers) as shown.

[0097] The tile units 604 are arranged on the framework 602 m a grid 606 having rows and columns. In this example one side of the grid 606 forms a pick face 610, which may be the first pick face 104 and / or second pick face 108 as described above. For the purpose of this description, in these examples the rows extend parallel to the pick face 610 and the columns perpendicularly to the rows.

[0098] The tile units 604 that form the grid 606 are arranged side-by-side in the rows and columns so that no gap, or a small gap, is provided between adjacent tile units 604. As described below, a storage container 608 can be supported on each tile unit 604 and driven from one tile unit 604 to an adjacent tile unit 604 in a row direction or in a column direction.

[0099] In the illustrated example the automated storage system 600 comprises a plurality of levels 612 - 622. In particular, the automated storage system 600 includes a top level 622, a bottom level 612, and, in this example, four intermediate levels 614 - 620. The levels 612 - 622 are stacked on top of each other and defined by the framework 602. In this example the levels 612 - 622 are aligned but in some examples, depending on the particular installation, they need not be aligned. One or more lifts 630 may be provided for moving storage containers 608 between levels 612 - 622. The lifts 630 may include a tile unit 604 that can be moved vertically into alignment with different levels 612 - 622 and can therefore be operated to move a storage container 608 between two of the levels 612 - 622.

[0100] As shown, in the example of FIG. 6 the automated storage system 600 includes a conveyor 632 extending along the pick face 610. The conveyor 632 is arranged to receive storage containers 608 from the grid 606 and present them to an operator for retrieval of goods (or retrieval of the storage containers 608 themselves). Storage containers 608 may then be moved back into the grid 606. In the illustrated example the lifts 630 are arranged to move storage containers 608 between the levels 612 - 622 and the conveyor 632. In other examples, the lifts 630 may be positioned in a different part of the grid 606 and the storage containers 608 may move directly onto the conveyor 632 from at least one of the levels 612 - 622. The conveyor 632 may comprise one or more tile units 604 for moving storage containers 608 along the conveyor 632. The conveyor 632 may move storage containers 608 to a specific pick location along the conveyor 632.

[0101] In some examples, the pick face 610 may comprise a conveyor 632 extending partially along the pick face 610 and the remainder of the pick face 610 may be formed in the same manner as the pick face 510 described with reference to FIG. 5 above.

[0102] In the example of FIG. 5 and FIG. 6 the automated storage systems 500, 600 have a plurality of levels. However, as illustrated in FIG. 7, in other examples the automated storage system 700 may comprise only one level. Providing more levels increases the storage density per unit of floor area, and different storage densities can be provided for different applications. However, it may also reduce the size of the storage containers that can be stored by reducing head space, and in some applications only a single level may be provided, particularly when the storage containers are taller (e.g., trolleys or cages).

[0103] The example automated storage system 700 of FIG. 7 may be provided on the floor of a warehouse and the storage containers 708 may be larger (taller), for example trolleys, pallets, or cages, which may make multiple levels unfeasible. Alternatively, the single level of the automated storage system 700 may be provided in an elevated position (e.g., waist height) to ease retrieval of goods from the pick face 706 by an operator.

[0104] In the example of FIG. 7 the pick face 706 comprises an edge row 702 of tile units 704. The edge row 702 extends along the pick face 706 and storage containers 708 can be moved into, out of, and / or along the edge row 702 and the pick face 706.

[0105] In each of the examples of FIG. 5, FIG. 6, and FIG. 7 it will be appreciated that some of the tile units 504, 604, 704 provide an area for storing, collating, or sorting storage containers 508, 608, 708. Therefore, storage containers 508, 608, 708 can be stored in the automated storage system 500, 600, 700 and moved to the pick face 510, 610, 706 when they are ‘called’ - i.e., when goods are to be retrieved from those storage containers 508, 608, 708. Additionally, storage containers 508, 608, 708 may be collated into groups or sorted into a particular order within the storage area, spaced from the pick face 510, 610, 706, in preparation or anticipation of being moved in the pick face 510, 610, 706 at a future time. Accordingly, the automated storage system 500, 600, 700 can be operated to present the ‘called’ storage containers 508, 608, 706 at the pick face 510, 610, 706 at the appropriate time and in the appropriate order.

[0106] Visual and / or audible indicators may be provided at the pick face 510, 610, 706 informing an operator or robot about which goods to pick from which storage containers 508, 608, 708 and at what time or in what order. Visual indicators may be lights or a display screen, and audible indicators may be provided by loudspeakers or headphones. The same indicators may be used to inform the operator or robot which receiving containers retrieved goods should be placed in. Accordingly, an operator or robot is informed which goods to retrieve, in what order, and where to deposit them.

[0107] FIG. 8 shows a magnified view of one part of the grid 506 of tile units 504 of the automated storage system 500 described with reference to FIG. 5. However, it will be appreciated that this also applies to the examples of FIG. 6 and FIG. 7.

[0108] As shown, the illustrated storage container 508 is supported on a tile unit 504 of the grid 506. As explained further hereinafter, each tile unit 504 has a drive unit (described further below) that can be operated to move the storage container 508 to an adjacent tile unit 504 in a row direction or a column direction. Specifically, the tile unit 504 has a drive unit operable to move the storage container 508 in a row direction to either adjacent tile unit 802b or adjacent tile unit 802c, or in a column direction to ether adjacent tile unit 802a or adjacent tile unit 802d.

[0109] The automated storage system 500 includes a control system that controls each of the tile units 504. The control system may also track the positions of each storage container 508 on the grid 506 and may also track the contents of each storage container 508. The control system also receives or processes information about which goods are to be retrieved from the pick face 510, and an associated order or timing profile.

[0110] The control system can thereby control the tile units 504 so that goods are stored in the automated storage system 500 until they are needed at the pick face 510, at which time the relevant storage containers 508 can be moved across the grid 506 and into the pick face 510.

[0111] FIG. 9A to FIG. 9C show an example tile unit 504 of the automated storage system 500 described above, but may also be the tile unit 604 of the example automated storage system 600 of FIG. 6, or the tile unit 704 of the example automated storage system 700 of FIG. 7.

[0112] The tile unit 504 has a housing 902 and a drive unit 912 located within the housing 902. In this example, the drive unit 912 comprises four drive wheels 906a - 906d. The drive wheels 906a - 906d protrude through openings in a top 904 of the tile unit 504 so that the drive wheels 906a - 906d protrude beyond a top surface of the housing 902. The tile unit 504 additionally comprises guide rollers 908b - 908d. The guide rollers 908b - 908d are ball rollers secured at corners of the housing 902 on the top surface and help to guide storage containers as they move between adjacent tile units 504 and to support edges of the storage containers and / or skid plates.

[0113] When a storage container is supported on the tile unit 504 it is supported on the drive wheels 906a - 906d and optionally on the guide rollers 908b - 908d.

[0114] As shown in FIG. 9B and FIG. 9C, the drive unit 912 includes a motor 916a - 916d for each drive wheel 906a - 906d. The motors 916a - 916d are coupled to the drive wheels 906a -906d and operable to rotate the drive wheels 906a - 906d about their rotational axis, which causes a storage container to move in a row direction or in a column direction. [0H5] As shown in FIG. 9B and FIG. 9C, the drive unit 912 also includes a swivel mechanism 918. The swivel mechanism 918 is housed within the housing 902. The swivel mechanism 918 is operable to swivel the drive wheels 906a - 906d about swivel axes that are normal to the top 904 of the housing 902 and intersect the centres of the drive wheels 906a -906d. In this way, the swivel mechanism 918 is operable to swivel the drive wheels 906a -906d through at least 90 degrees of rotation to change their orientation from a row direction to a column direction. In examples, the swivel mechanism 918 is operable to swivel the drive wheels 906a - 906d through 90 degrees, which in combination with rotating the drive wheels 906a - 906d in either direction allows for a storage container to be driven to an adjacent tile unit 504 in a row direction or in a column direction.

[0116] In particular, as shown in FIG. 9C, each drive wheel 906a - 906d and associated motor 916a - 916d is mounted to a respective pivot 914a - 914d that is pivotally mounted to the housing 902 about the swivel axis of the drive wheels 906a - 906d. An actuator plate 920 joins each of the pivots 914a - 914d to a lead nut 922 that is mounted on a lead shaft 924 of a pivot motor 926. The actuator plate 920 is pivotally and slidably mounted (e.g., at a slot) to each pivot 914a - 914d at a point offset from the respective swivel axis. The lead shaft 924 and pivot motor 926 are fixed within the housing 902. Accordingly, operating the pivot motor 926 rotates the lead shaft 924 and moves the lead nut 922 along the lead shaft 924. This movement moves the actuator plate 920 in a sideways direction (left or right as illustrated), which causes rotation of the pivots 914a - 914d and thus swivelling of the drive wheels 906a - 906d.

[0117] It will be appreciated that the drive wheels 906a - 906d are not lowered or raised when changing orientation, and the drive wheels 906a - 906d are swivelled about their swivel axes while in contact with a storage container supported on the tile unit 504. Advantageously, swivelling the drive wheels 906a - 906d in this way helps to prevent unintended movement of the storage container.

[0118] In examples, the swivel mechanism 918 acts to swivel at least some of the drive wheels 906a - 906d in opposite directions. In particular, in the example of FIG. 9C the actuator plate 920 is attached to the pivots 914a - 914d such that operation of the pivot motor 926 to move the actuator plate 920 rightwards would cause clockwise swivelling of drive wheels 906c and 906d, and counterclockwise swivelling of drive wheels 906a and 906b. This may help to reduce any rotation imparted on the storage container during operation of the swivel mechanism 918. [0H9] As also shown in FIG. 9A, the tile unit 504 comprises a sensor 910. The sensor 910 is provided on the top 904 of the housing 902. The sensor 910 is arranged to detect a presence / movement of a storage container, and / or to read an identity of a storage container on the tile unit 504. The sensor 910 is positioned on the tile unit 504, in particular on the top 904 of the housing 902, so as to ‘read’ upwards. In one example, the sensor 910 comprises a resonant inductive sensor to sense movement of a storage container over and across the sensor 910. In other examples, the sensor 910 could be an optical sensor or similar. The sensor 910 will trigger when a storage container moves over it, and off it. In other examples, the sensor 910 may comprise an RFID receiver or barcode scanner that reads a corresponding feature (RFID tag or barcode) on the storage container to identify the storage container.

[0120] The control system described is configured to be programmed with the location of each tile unit 504 within the grid 506 through an addressing process when the grid 506 is assembled or commissioned. The control system may track the location of each storage container 508, for example by recoding movements of storage containers and / or by using sensor signals from the various sensors sensor 910 of the tile units 504. Information received from the sensors sensor 910 may additionally or alternatively be used to confirm that storage containers have moved from one tile unit 504 to another as instructed by the control system (i.e., to verify operation of the drive units 912).

[0121] FIG. 10 illustrates a different example tile unit 504 of the automated storage system 500 illustrated in FIG. 5, which also applies to the tile units 704 of the example automated storage system 700 of FIG. 7.

[0122] The tile unit 504 of FIG. 10 is similar to that of FIG. 9A to FIG. 9C in that it has a housing 902 and a drive unit located within the housing 902. The drive unit includes drive wheels 906a - 906d that protrude through a top 904 of the housing 902 and support a storage container received thereon. The drive unit also includes a swivel mechanism, which may be the same or similar to as described above, that swivels the drive wheels 906a - 906d between a row direction and a column direction. The tile unit 504 of FIG. 10 may be used for heavier storage containers than the tile unit 504 of FIG. 9A to FIG. 9C.

[0123] In this example the tile unit 504 also includes edge rollers 1002a, 1002b arranged on one edge of the housing 902, and edge rollers 1004a, 1004b arranged on a perpendicular edge. The edge rollers 1002a - 1004b are arranged to support and guide a storage container as it moves across that edge (either on to, or off of, the tile unit 504).

[0124] Additionally, in this example the tile unit 504 includes guide rollers 1006a - 1006d that are arranged between the drive wheels 906a - 906d and protrude above the top 904 in the same way as the drive wheels 906a - 906d. The guide rollers 1006a - 1006d are parallel to the drive wheels 906a - 906d and are attached to the swivel mechanism so that they swivel with the drive wheels 906a - 906d. The guide rollers 1006a - 1006d may swivel in the same or opposite directions as the drive wheels 906a - 906d. The guide rollers 1006a - 1006d swivel about swivel axes that are normal to the top 904 and intersect a centre of the guide rollers 1006a -1006d. The guide rollers 1006a - 1006d do not have a motor so do not drive the storage containers. The guide rollers 1006a - 1006d may help to support the weight of the storage containers and to guide them straight as they are moved between tile units 504.

[0125] FIG. 11 illustrates a part of the grid 506 of tile units 504 of the automated storage system 500 of FIG. 5, and may also apply to the automated storage system 600 of FIG. 6 and the automated storage system 700 of FIG. 7. In this example the tile units 504 are those illustrated in FIG. 10, but it will be appreciated that in other examples the tile units 504 could be those of FIG. 9A to FIG. 9C instead.

[0126] As shown, the tile units 504 are aligned within the framework 502 in rows and columns. The framework 502 includes a seat 1102 for each tile unit 504. Each seat 1102 is adapted to receive and support a tile unit 504. In examples, the tile units 504 are insertable into the seats 1102 from above. In this way, tile units 504 can be assembled into the grid 506 by lowering them into the seats 1102 of the framework 502, and can be lifted out of the seats 1102 for removal from the grid 506. This may allow tile units 504 to be retrieved from the automated storage system 500 without having to remove any other components.

[0127] As shown, in this example the tile units 504 are arranged with no or very little space between them, for example abutting each other along the sides of the housings 902 (see FIG. 9A and FIG. 10). In other examples, the framework 502 may separate the tile units 504 from each other by a small distance.

[0128] As shown in FIG. 11, the tile units 504 support a storage container 508. In some examples, the storage containers 508 are supported directly on the tile units 504, in particular on the drive wheels 906a - 906d (see FIG. 9A and FIG. 10). That is, the undersides of the storage containers 508 contact the drive wheels 906a - 906d. In other examples, as shown in FIG. 11, a skid plate 1104 is provided on the tile units 504. Goods, which may be in a storage container 508, can be positioned on top of the skid plate 1104. In this example, the skid plate 1104 is supported by the drive wheels 906a - 906d. In some examples, the automated storage system 500 may have a mix of storage containers 508 received directly on the tile units 504 and skid plates 1104 on which goods and / or storage containers 508 are positioned. The skid plate 1104 may allow for goods to be placed directly on the skid plate 1104 without a storage container 508, for example if the goods are already packaged in a box or other container.

[0129] As mentioned above, a support drive system, for example a trolley drive system, may be provided in the pick area (between the first pick face 104 and the second pick face 108). In such examples, the support drive system may comprise tile units 504 arranged in one or more rows similar to as illustrated in FIG. 11. In particular, the support drive system may comprise two rows of tile units 504 such that supports (e.g., trolleys 112) can be moved past each other on the support drive system.

[0130] FIG. 12 shows the underside of a skid plate 1104, which is in contact with the drive wheels 806a- 906d of the tile units 504 during use. The same pattern, described below, may alternatively or additionally be provided on the underside of the storage containers 508, particularly when the storage containers 508 are received directly on the tile units 504 without a skid plate 1104.

[0131] As shown, the underside of the skid plate 1104 comprises a number of wheel guides 1202. The wheel guides 1202 define grooves within which the drive wheels 906a - 906d and any guide wheels are received, and act to maintain alignment of the skid plate 1104 or storage container 508 as it is moved from one tile unit 504 to an adjacent tile unit 504.

[0132] As shown in FIG. 12, swivel areas 1204 are provided within the wheel guide 1202. At the swivel areas 1204 the recess is enlarged and permits the drive wheels 906a - 906d to swivel, as described above, without hitting the sides of the wheel guides 1202. Swivel areas 1204 may also be provided for any guide wheels that swivel, such as the guide rollers 1006a - 1006d shown in FIG. 10.

[0133] 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.

[0134] 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 or process 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

1. An order processing system comprising:a first storage system for a first set of goods held in goods transport means, the first storage system comprising an automated storage system having:a framework,a plurality of tile units arranged on the framework in a grid of columns and rows, wherein each of the plurality of tile units is configured to support one of the goods transport means holding the first set of goods and comprises a drive unit operable to move the goods transport means to an adjacent tile unit in a column direction or in a row direction,a first pick face formed at an edge of the grid at which the first set of goods are accessible for retrieval, anda control system operable to individually control the tile units to move the goods transport means around the grid and into, and out of, the first pick face;wherein the order processing system further comprises a second storage system for a second set of goods and having a second pick face at which the second set of goods are accessible for retrieval,wherein the first storage system and the second storage system are arranged such that the first pick face is adjacent to the second pick face,and wherein the order processing system further comprises a pick area between the first pick face and the second pick face, the pick area comprising a support for receiving goods retrieved from the first pick face and the second pick face.

2. The order processing system of claim 1, wherein the support is moveable along the pick area between the first pick face and the second pick face.

3. An order processing system comprising:an automated storage system comprising:a framework,a plurality of tile units arranged on the framework in a grid of columns and rows, wherein each of the plurality of tile units is configured to support a goods transport means holding goods and comprises a drive unit operable to move the goods transport means to an adjacent tile unit in a column direction or in a row direction,a pick face formed at an edge of the grid at which the goods are accessible for retrieval,anda control system operable to individually control the plurality of tile units to move the goods transport means around the grid and into, and out of, the pick face; anda support for receiving goods retrieved from the goods transport means at the pick face, wherein the support is disposed adjacent to the pick face and is moveable along the pick face.

4. The order processing system of claim 3, wherein the pick face is a first pick face, and wherein the order processing system further comprises a second storage system having a second pick face arranged adjacent to the first pick face and defining a pick area between the first pick face and the second pick face, and wherein the automated storage system holds a first set of goods and the second storage system holds a second set of goods.

5. The order processing system of claim 4, wherein the second pick face is arranged on a different side of the pick area to the first pick face, for example on an opposite side.

6. The order processing system of any one of claims 1-2 or 4-5, wherein the second storage system comprises a racking system.

7. The order processing system of claim 6, wherein the racking system comprises a plurality of lanes for receiving goods transport means holding the second set of goods.

8. The order processing system of claim 7, wherein the goods transport means in each lane of the racking system hold the same goods.

9. The order processing system of claim 7 or 8, wherein the racking system comprises a flow racking system, and wherein the goods transport means are urged along each lane towards the second pick face.

10. The order processing system of any one of claims 1-2 or 4-5, wherein the second storage system is adapted to receive goods in goods transport means, for example containers, pallets, trolleys, or cages.

11. The order processing system of any one of claims 1-2 or 4-5, wherein the second storage system comprises an automated storage system for the second set of goods held in goods transport means, the automated storage system comprising:a framework,a plurality of tile units arranged on the framework in a grid of columns and rows, wherein each of the plurality of tile units is configured to support one of the goods transport means holding the second set of goods and comprises a drive unit operable to move the goods transport means to an adjacent tile unit in a column direction or in a row direction,a second pick face formed at an edge of the grid at which the second set of goods are accessible for retrieval, anda control system operable to individually control the tile units to move goods transport means around the grid and into, and out of, the second pick face.

12. The order processing system of claims 1-2 or 4-11, wherein the first storage system holds a first set of goods transport means and the second storage system holds a second set of goods transport means.

13. The order processing system of any one of claims 1-2 or 4-12, wherein the first set of goods have a first expected retrieval frequency, and wherein the second set of goods have a second expected retrieval frequency, the first expected retrieval frequency being different to the second expected retrieval frequency.

14. The order processing system of claim 13, wherein the second expected retrieval frequency is higher than the first expected retrieval frequency.

15. The order processing system of claim 13 or 14, further comprising a third storage system for storing a third set of goods having a third expected retrieval frequency, the third expected retrieval frequency being lower than the first expected retrieval frequency and the second expected retrieval frequency.

16. The order processing system of claim 15, wherein the third storage system is arranged at one end of the pick area, or away from the pick area.

17. The order processing system of claim 15 or 16, further comprising a transfer system for transferring goods from the third storage system to the pick area or to the automated storage system.

18. The order processing system of any one of claims 1-2, or 4-17, wherein the first pick face is spaced from the second pick face by no more than 5 metres, for example less than 5 metres, for example less than 3 metres, for example less than 2 metres.

19. The order processing system of any preceding claim, wherein the support is adapted to hold a plurality of receiving containers for receiving goods.

20. The order processing system of any preceding claim, further comprising a support drive system operable to move the support.

21. The order processing system of claim 20, wherein the support drive system comprises a plurality of tile units arranged to form a conveyor, each of the plurality of tile units configured to support the support and comprising a drive unit operable to move the support to an adjacent tile unit.

22. The order processing system of claim 21, wherein the support drive system comprises at least two rows of tile units.

23. The order processing system of claim any preceding claim, wherein the support comprises a trolley.

24. The order processing system of any preceding claim, wherein at least one of the or each pick face comprises a row of tile units.

25. The order processing system of claim any preceding claim, wherein at least one of the or each automated storage system comprises a conveyor extending at least partially along the pick face.

26. The order processing system of any preceding claim, wherein at least one of the or each framework comprises more than one vertically-stacked level, each level having a plurality of tile units arranged in rows and columns and forming a grid of tile units.

27. The order processing system of claim 26, further comprising at least one lift for moving goods transport means between levels.

28. The order processing system of claim 26 or claim 27, wherein at least one of the or each pick face comprises a first edge row of tile units formed at an edge of a first level, and a spaceabove the first edge row to allow retrieval of goods from goods transport means on the first edge row.

29. The order processing system of claim 28, wherein at least one of the or each pick face further comprises a second edge row of tile units formed at an edge of a second level.

30. The order processing system of claim 29, wherein at least one of the or each automated storage system further comprises an intermediate level between the first level and the second level, the first level being below the intermediate level, and wherein the intermediate level comprises an intermediate edge row of tile units offset from the first edge row to define the space above the first edge row.

31. The order processing system of any preceding claim, wherein each drive unit comprises a drive wheel operable to engage a goods transport means supported on the tile unit and to move the goods transport means to an adjacent tile unit.

32. The order processing system of claim 31, wherein each drive wheel is swivelable through 90 degrees such that the drive wheel can move the goods transport means in a row direction or in a column direction.

33. The order processing system of claim 31 or 32, wherein each drive unit comprises a plurality of drive wheels, for example two, three or four drive wheels.

34. The order processing system of any one of claims 31 to 33, wherein the or each drive wheel is fixed in a vertical direction.

35. The order processing system of claim 34, wherein a plurality of the tile units of at least one of the or each automated storage system define a storage area for storing goods transport means.

36. The order processing system of any preceding claim, wherein the goods transport means comprises a storage container.

37. The order processing system of any preceding claim of any preceding claim, wherein the goods transport means comprises a skid plate.

38. A method of order processing, the method comprising:storing a first set of goods in a first storage system, the first storage system being an automated storage system adapted to store the first set of goods in goods transport means and operable to move the goods transport means to a first pick face of the automated storage system for retrieval of goods therefrom,storing a second set of goods in a second storage system, the second storage system having a second pick face for retrieval of goods therefrom, wherein the second pick face is adjacent to the first pick face in a pick area, andretrieving goods from the first pick face and the second pick face for order fulfilment, wherein the first set of goods has a lower expected retrieval frequency than the second set of goods.

39. The method of claim 38, wherein the second set of goods comprises fewer different types of goods than the first set of goods.

40. The method of claim 38 or 39, comprising retrieving multiple of a type of goods from the first pick face or the second pick face and depositing the retrieved goods in a plurality of retrieval receiving containers.

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