Picking systems and methods

Abstract

To provide systems for pickling items from a containerized storage system.SOLUTION: Items 28 are stored in storage bins 10 in stacks within a framework comprising a grid system 22 disposed above the stacks of the bins 10. Robotic devices 130 are disposed on the grids 22, the devices 130 acting so as to pick containers DT1, 2 from the stacks of the bins 10. The storage system is provided with at least one pickling device 130 for picking the items 28 from the bins 10 and depositing them directly in the delivery containers DT1, 2.SELECTED DRAWING: Figure 6a

Description

[Technical field]

[0001] The present invention relates to a picking system and method, and more particularly, but not by way of limitation, the present invention relates to a robotic picking system for picking objects from a storage system having storage bins in stacks, the stacks being arranged in a grid structure.

[0002] This application claims priority to UK Patent Application No. 1519931.8, UK Patent Application No. 1519930.0, and UK Patent Application No. 1519929.2, filed on November 11, 2015, the entire contents of which are incorporated herein by reference. [Background technology]

[0003] Some commercial and industrial activities require systems that allow for the storage and retrieval of a large number of different products. One known type of system for storing and retrieving items in multiple production lines involves placing storage bins or containers in stacks on top of each other, with the stacks arranged in rows. Storage bins are removed from the stacks and accessed from above by load handling equipment, thereby eliminating the need for aisles between the rows and allowing more containers to be stored in a given space.

[0004] Methods for handling containers stacked in rows have been known for many years. Some such systems, such as those described in U.S. Patent No. 2,701,065 to Bertel, comprise freestanding container stacks arranged in rows to reduce the storage volume associated with storing such containers while still providing access to a particular container as needed. Access to a given container is made possible by providing a relatively complex hoisting mechanism that can be used to stack and retrieve a given container from the stack. However, the cost of such systems makes them impractical in many situations and they have been primarily commercialized for storing and handling large shipping containers.

[0005] The concept of using freestanding container stacks and providing mechanisms for retrieving and storing specific containers has been further developed, for example as described in EP0767113B to Cimcorp. EP0767113B discloses a mechanism for removing multiple stacked containers using a robotic load handler in the form of a rectangular tube that is lowered around the container stack and configured to grasp a container at any level of the stack. In this way, multiple containers can be lifted from the stack in unison. The movable tube can be used to move multiple containers from the top of one stack to the top of another stack, or to move containers from the stack to an external location and vice versa. Such a system can be particularly useful where all containers in a single stack contain the same product (known as a single product stack).

[0006] In the system described in EP0767113B the height of the tubes must be at least as high as the height of the largest container stack so that the tallest container stack can be extracted in a single operation, and therefore when used in enclosed spaces such as warehouses the maximum height of the stack is constrained by the need to accommodate the tubes of the load handler.

[0007] EP1037828B1 (Autostore), the contents of which are incorporated herein by reference, describes a system in which a stack of containers is arranged within a frame structure. A system of this type is shown diagrammatically in Figures 1 to 4 of the accompanying drawings. A robotic load handling device can be controllably moved around the stack on a track system on the top surface of the stack.

[0008] Other forms of robotic load handling equipment are further described, for example, in Norwegian Patent No. 317366, the contents of which are incorporated herein by reference. Figures 3a and 3b are schematic perspective views of the load handling equipment from the rear and front respectively, and Figure 3c is a schematic front perspective view of the load handling equipment lifting a box.

[0009] A further development of load handling equipment is described in UK Patent Application No. 1314313.6 to Ocado Innovation Limited, where each robotic load handler serves only one grid space, thus allowing a higher density of load handlers and therefore a higher throughput for a system of a given size. However, any suitable form of load handling equipment may be used.

[0010] In the known robotic picking systems mentioned above, a robotic load handling device is controllably moved around the top of the stack on a track system forming a grid. A given load handling device lifts a box from the stack, a container being a lifter containing the stock items required to fulfill a customer order. The container is transported to a pick station where the required stock items can be manually removed from the box and placed in a shipping container. The shipping container, forming part of the customer order, is manually filled for timely dispatch. At the pick station, the items can also be picked by an industrial robot suitable for such operations, for example as described in UK Patent Application No. 1502123.1 of Ocado Innovation Limited.

[0011] It will be appreciated that this picking of inventory items from storage bins into shipping containers creates delays at the pick stations, which in turn creates congestion at the pick stations and delays in collecting customer orders. Furthermore, the pick stations themselves represent a significant investment expense whether designed for manual or robotic picking. Summary of the Invention

[0012] According to the invention there is provided a picking system for a storage system comprising a first set of parallel rails or tracks and a second set of parallel rails or tracks extending substantially perpendicular to the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, a set of uprights supporting the tracks, the uprights and the tracks together defining a framework, and a plurality of containers located below the tracks and within the framework, a portion of said containers occupying a space below the grid spaces, the storage system further comprising picking means arranged above the containers, at least one of which comprises an inventory item, the picking means being adapted to pick at least one inventory item from the at least one container and to deposit the or each inventory item into at least one or more further containers.

[0013] According to the invention, there is provided a method of picking inventory items from a storage system comprising a first set of parallel rails or tracks, a second set of parallel rails or tracks extending substantially perpendicular to the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, a set of uprights supporting the tracks, the uprights and tracks together defining a framework, and a plurality of containers located below the tracks and within the framework, each container occupying a space below a grid space, the method comprising the steps of placing at least one first container comprising a target inventory item to be picked, placing at least one second container into which the target inventory item is unloaded, transferring at least one item from the at least one container to the at least one second container, and transferring the item directly from the at least one container to the at least one second container by a picking means located on or above the grid.

[0014] In this way, a portion of a customer order, or some or all of the customer order, may be picked by the robot directly on the grid, which reduces the amount of manual intervention required in the system, improving efficiency and reducing costs.

[0015] In doing so, the present invention provides a system and method that overcomes the problems of the prior art, increases the speed at which customer orders are compiled, reduces the overall cost, and improves the efficiency of large box handling storage and picking systems.

[0016] The invention will now be described with reference to the accompanying schematic drawings. [Brief description of the drawings]

[0017] [Figure 1] 1 is a schematic perspective view of a frame structure for accommodating multiple box stacks within a storage system; FIG. [Diagram 2] FIG. 2 is a schematic plan view of a portion of the frame structure of FIG. 1; [Figure 3a] FIG. 3 is a schematic front perspective view of one form of robotic load handling apparatus for use with the frame structure of FIGS. 1 and 2; [Figure 3b-3c] 3 is a schematic rear perspective view of one form of robotic load handling apparatus for use with the frame structure of FIGS. 1 and 2, and a schematic perspective view of a known load handler apparatus in use lifting a box; [Figure 4] FIG. 3 is a schematic perspective view of a known storage system including a plurality of load handler apparatus of the type shown in FIGS. 3a, 3b and 3c mounted on the frame structure of FIGS. 1 and 2 together with a robotic load handling apparatus according to one embodiment of the present invention; [Diagram 5] 1 is a schematic perspective view of one embodiment of a robotic picking area according to one aspect of the present invention, the robotic picking area is located above a shipping dock and includes a series of grids forming tracks above a number of shipping containers; [Figure 6a]5 is a schematic cutaway perspective view of one configuration of a robotic picking device according to a first embodiment of the present invention, the robotic picking device picking an inventory item 28 from a bin located within the robotic picking area of ​​FIG. [Figure 6b] Figure 6a is a schematic cutaway perspective view of one form of robotic picking device according to a first embodiment of the present invention, the robotic picking device lowering picked items from Figure 6a into a shipping container located in the robotic picking area of ​​Figure 5, the shipping container being pre-loaded with shipping bags; [Figure 7] FIG. 1 is a schematic perspective view of a robotic picking device according to a first embodiment of the present invention picking an inventory item from a bin in a stack in a primary storage system. [Figure 8a] 1 is a schematic cutaway perspective view of a further robotic picking device according to the invention, configured to lift a box containing inventory items from a storage system, pick the inventory items from the box, and deposit the picked items into a shipping container located in a dispatch portion of a grid, in a robotic picking area, or within the storage system; [Figure 8b] 8b is a schematic cutaway view of the shipping portion of FIG. 8a showing the robotic picking device of FIG. 8a lowering a robotically picked inventory item from the storage system directly into a shipping bin. [Figure 8c] 8b is a schematic cutaway view of the shipping portion of FIG. 8a showing the robotic picking device of FIG. 8a lowering a robotically picked inventory item from the storage system directly into a shipping bin. [Figure 8d] 8b is a schematic cutaway view of the shipping portion of FIG. 8a showing the robotic picking device of FIG. 8a lowering a robotically picked inventory item from the storage system directly into a shipping bin. [Figure 8e] 8b is a schematic cutaway view of the shipping portion of FIG. 8a showing the robotic picking device of FIG. 8a lowering a robotically picked inventory item from the storage system directly into a shipping bin. [Figure 8f]8b is a schematic cutaway view of the shipping portion of FIG. 8a showing the robotic picking device of FIG. 8a lowering a robotically picked inventory item from the storage system directly into a shipping bin. [Figure 8g] 8a is a schematic cutaway view of a portion of the storage system of FIG. 5 showing the robotic picking device of FIG. 8a picking inventory items from bins in a grid and depositing those inventory items along with shipping containers held within the body of the robotic picking device. [Figure 8h] 8a is a schematic cutaway view of a portion of the storage system of FIG. 5 showing the robotic picking device of FIG. 8a picking inventory items from bins in a grid and depositing those inventory items along with shipping containers held within the body of the robotic picking device. [Figure 8i] 8a is a schematic cutaway view of a portion of the storage system of FIG. 5 showing the robotic picking device of FIG. 8a picking inventory items from bins in a grid and depositing those inventory items along with shipping containers held within the body of the robotic picking device. [Figure 9a] FIG. 1 is a schematic cutaway perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device configured to receive bins containing inventory items from a storage system, pick the inventory items from the bins, and deposit the picked items into a shipping container located in a dispatch portion of a grid, in a robotic picking area of ​​the grid, or within the storage system. [Figure 9b] FIG. 1 is a schematic cutaway perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device configured to receive bins containing inventory items from a storage system, pick the inventory items from the bins, and deposit the picked items into a shipping container located in a dispatch portion of a grid, in a robotic picking area of ​​the grid, or within the storage system. [Figure 9c]FIG. 1 is a schematic cutaway perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device configured to receive bins containing inventory items from a storage system, pick the inventory items from the bins, and deposit the picked items into a shipping container located in a dispatch portion of a grid, in a robotic picking area of ​​the grid, or within the storage system. [Figure 9d] FIG. 1 is a schematic cutaway perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device configured to receive bins containing inventory items from a storage system, pick the inventory items from the bins, and deposit the picked items into a shipping container located in a dispatch portion of a grid, in a robotic picking area of ​​the grid, or within the storage system. [Figure 9e] FIG. 1 is a schematic cutaway perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device configured to receive bins containing inventory items from a storage system, pick the inventory items from the bins, and deposit the picked items into a shipping container located in a dispatch portion of a grid, in a robotic picking area of ​​the grid, or within the storage system. [Figure 9f] FIG. 1 is a schematic cutaway perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device configured to receive bins containing inventory items from a storage system, pick the inventory items from the bins, and deposit the picked items into a shipping container located in a dispatch portion of a grid, in a robotic picking area of ​​the grid, or within the storage system. [Figure 10a] 1 is a schematic perspective view of a further form of robotic device according to the present invention, the robotic device including an opening in a top surface of a vehicle body thereby extending a cavity through the robotic device, the extending cavity allowing the contents of a box or shipping container to be accessed through the top of the device; [Figure 10b] 10b is a schematic perspective view of the robotic device of FIG. 10a showing the shipping container in situ within the extended cavity. [Figure 10c] 10a and 10b on a grid of a storage system, the system further comprising a robotic picking means configured to access contents of a shipping container or box located within a cavity of the robotic device, the robotic picking means picking an inventory item from one of a plurality of robotic devices located on the grid of the storage system. [Figure 10d] 10a and 10b on a grid of a storage system, the system further comprising a robotic picking means configured to be transported on a further form of robotic device for picking an inventory item from one of a plurality of robotic devices located on the grid of the storage system and placing said inventory item in a robotic device comprising a shipping container. [Figure 11a] FIG. 6 is a schematic perspective view of a robotic picking device according to a further embodiment of the present invention, the robotic picking device being movably mounted on an edge of a storage system, the robotic picking device picking inventory items from within a portion of the storage system of FIG. 5 and depositing the inventory items into shipping containers located within the storage system. [Figure 11b] FIG. 6 is a schematic perspective view of a robotic picking device according to a further embodiment of the present invention, the robotic picking device being movably mounted on an edge of a storage system, the robotic picking device picking inventory items from within a portion of the storage system of FIG. 5 and depositing the inventory items into shipping containers located within the storage system. [Figure 12a] FIG. 1 is a schematic perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device being movably mounted above a storage system and movable to a position above any storage bin or shipping container within the storage system and adapted to pick a plurality of inventory items directly from at least one storage bin and deposit the plurality of inventory items, or each inventory item, into at least one shipping container; [Figure 12b]FIG. 1 is a schematic perspective view of a robotic picking device according to a further aspect of the present invention, the robotic picking device being movably mounted above a storage system and movable to a position above any storage bin or shipping container within the storage system and configured to pick an inventory item directly from at least one storage bin and deposit the or each item into at least one shipping container; [Figure 13a] 1 is a schematic perspective cutaway view of a further box according to the invention, the box comprising a number of dispenser mechanisms capable of automatically and remotely controlled unloading items from the box into a shipping container; [Figure 13b] 1 is a schematic perspective cutaway view of a further box according to the invention, the box comprising a number of dispenser mechanisms capable of automatically and remotely controlled unloading items from the box into a shipping container; [Figure 13c] 1 is a schematic perspective cutaway view of a further box according to the invention, the box comprising a number of dispenser mechanisms capable of automatically and remotely controlled unloading items from the box into a shipping container; [Figure 13d] Fig. 13 is a schematic perspective view of a further robotic handling device according to the invention, the robotic handling device comprising means for lifting and transporting the boxes of Figs. 13a, 13b and 13c for dispensing the inventory items contained therein into shipping containers located in a portion of a storage system. [Figure 14a] 1 is a schematic diagram of a further embodiment of the present invention showing a box with a mechanism for retracting a bottom section of the box, the bottom section moving between a first position where an inventory item is retained within the box and a second position where an inventory item is ejected from the box. [Figure 14b] 1 is a schematic diagram of a further embodiment of the present invention showing a box with a mechanism for retracting a bottom section of the box, the bottom section moving between a first position where an inventory item is retained within the box and a second position where an inventory item is ejected from the box. [Figure 14c]1 is a schematic diagram of a further embodiment of the present invention showing a box with a mechanism for retracting a bottom section of the box, the bottom section moving between a first position where an inventory item is retained within the box and a second position where an inventory item is ejected from the box. [Figure 14d] FIG. 14 is a schematic diagram of one form of mechanism for moving the bottom section of the box of FIGS. 14a, 14b and 14c from a first position to a second position. [Figure 14e] 1 is a schematic cutaway view of a further form of robotic handling device transporting a box, the box having a bottom that is movable from a first closed position to a second open position, with inventory items shown dropping from the box into a shipping container as the bottom of the box moves to the second open position; [Figure 15a] 1 is a schematic diagram of a further form of box having a bottom section that is movable from a first position to a second position, the box having a bottom with multiple sections that are independently movable from a first position to a second position to allow inventory items located within the box to be controllably lowered into specific portions of a shipping container. [Figure 15b] 15b is a schematic cutaway view of a further form of robotic load handling equipment according to an embodiment of the present invention transporting the box of FIG 15a, where the inventory item is shown being lowered into a given bagged portion of a lower shipping container. [Figure 16a] 1 is a schematic diagram of a further box according to a further aspect of the present invention, the box comprising an alternative embodiment of a mechanism for moving a bottom section of the box from a first position to a second position such that inventory items held within the box may drop into a shipping container below. [Figure 16b] Figure 16b is a schematic cutaway view of a further form of robotic load handling equipment according to an embodiment of the present invention transporting the box of Figure 16a, with the inventory item shown being lowered into a shipping container below. [Figure 17] 1 is a schematic diagram of a further box according to a further aspect of the present invention, the box comprising an alternative embodiment of a mechanism for moving a bottom section of the box from a first position to a second position such that inventory items held within the box drop into a shipping container below. [Figure 18a] 1 is a schematic diagram of a box according to a further aspect of the invention, the box comprising an alternative mechanism for lowering inventory items located in a storage container into a shipping container below, the inventory items being of a floating type; [Figure 18b] Figure 18b is a schematic cutaway view of a further form of robotic load handling equipment in accordance with an embodiment of the present invention transporting the box of Figure 18a, with the inventory item shown being lowered into a shipping container below. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] As shown in Figures 1 and 2, stackable storage containers known as boxes 10 are stacked on top of each other to form a stack 12. The stack 12 is arranged within a frame structure 14 within a warehouse or manufacturing environment. Figure 1 is a schematic perspective view of the frame structure 14, and Figure 2 is a top view showing a single stack 12 of boxes 10 arranged within the frame structure 14. Each box 10 typically holds multiple products or inventory items 28, which may be the same or may each be of a different product type depending on the application. Additionally, the boxes 10 may be physically subdivided to accommodate multiple different inventory items 28.

[0019] In the following description, box 10 is used to represent a container intended for storage of inventory items 28, while shipping container DT is used to represent a container intended to be filled to fulfill a customer order placed by a customer. It will be understood that this terminology is used within this document for ease of reference and description. However, it should be noted that box 10 and container DT may be of the same shape and configuration. Furthermore, shipping container DT may be stored within box 10 in a storage system or any portion thereof.

[0020] The frame structure 14 comprises a plurality of upright members 16 supporting horizontal members 18, 20. A first set of parallel horizontal members 18 are arranged perpendicular to a second set of parallel horizontal members 20 to form a plurality of horizontal grid structures supported by the upright members 16. The members 16, 18, 20 are typically fabricated from metal. The boxes 10 are stacked between the members 16, 18, 20 of the frame structure 14 such that the frame structure 14 prevents horizontal movement of the stack 12 of boxes 10 and guides vertical movement of the boxes 10.

[0021] The top level of the frame structure 14 includes rails 22 arranged in a grid pattern across the top of the stack 12. With further reference to Figures 3 and 4, the rails 22 support a plurality of robotic load handling apparatus 30. A first set 22a of the plurality of rails 22 guides movement of the load handling apparatus 30 in a first direction (X) across the top of the frame structure 14, and a second set 22b of parallel rails 22 arranged perpendicular to the first set 22a guides movement of the load handling apparatus 30 in a second direction (Y) perpendicular to the first direction. In this manner, the rails 22 allow movement of the load handling apparatus 30 in two dimensions in the XY plane such that the load handling apparatus 30 may be moved to a position above any of the stacks 12.

[0022] Each load handling apparatus 30 comprises a vehicle 32 configured to move in the X and Y directions on the rails 22 of the frame structure 14 above the stack 12. A first set of wheels 34, consisting of a pair of wheels 34 at the front of the vehicle 32 and a pair of wheels 34 at the rear of the vehicle 32, are configured to engage two adjacent rails of the first set 22a of rails 22. Similarly, a second set of wheels 36, consisting of a pair of wheels 36 on each side of the vehicle 32, are configured to engage two adjacent rails of the second set 22b of rails 22. Each set of wheels 34, 36 can be raised and lowered such that either the first set of wheels 34 or the second set of wheels 36 are engaged with the respective set of rails 22a, 22b at any one time.

[0023] Once the first set of wheels 34 are engaged with the first set of rails 22a and the second set of wheels 36 are lifted off the rails 22, the wheels 34 can be driven by a drive mechanism (not shown) housed within the vehicle 32 to move the load handling equipment 30 in the X direction. To move the load handling equipment 30 in the Y direction, the first set of wheels 34 are lifted off the rails 22 and the second set of wheels 36 are lowered into engagement with the second set of rails 22a. The drive mechanism can then be used to drive the second set of wheels 36 to accomplish movement in the Y direction.

[0024] In this manner, one or more robotic load handling devices 30 can move around the top surface of the stacks 12 on the frame structure 14 as shown in Figure 4 under the control of a centralized control utility (not shown). Each robotic load handling device 30 includes lifting means 38 for lifting one or more boxes 10 from the stack 12 to access the required products.

[0025] The body of the vehicle 32 includes a cavity 40 sized to hold a box 10. The lifting means 38 includes a winch means and box gripper assembly 39. The lifting means lifts the box 10 from the stack 12 into the cavity 40 in the body of the vehicle 32.

[0026] In this manner, multiple products can be accessed from multiple locations within the grid and stack at any one time.

[0027] The robotic load handling device 30 picks boxes 10 containing inventory items 28 (not shown) therein and transports the boxes 10 to a pick station (not shown) where the required inventory items 28 are removed from the boxes 10 and placed into the boxes 10 with a shipping container DT. It is important to note that the shipping container DT may fit within the box 10. The box 10 may contain inventory items 28 or may contain a shipping container DT. Additionally, the shipping container DT may contain at least one bag 52 and the inventory items 28 are picked directly into the bag 52 at the pick station (not shown).

[0028] Either empty boxes 10 or boxes with shipping containers DT, or boxes with shipping containers DT and bags 52 may be stored in the stack 12. It will be appreciated that all boxes 10 have substantially the same external shape and configuration.

[0029] FIG. 4 shows a typical storage system as described above, which has a number of load handling devices 30 operating on a grid above the stacks 12 .

[0030] 1 and 4 show boxes 10 in stacks 12 in a storage system. It will be appreciated that there may be many boxes 10 in any given storage system and that many different items 28 may be stored within the boxes 10 in the stacks 12, with each box 10 containing different categories of inventory items 28 within a single stack 12.

[0031] In the system described above and further in Ocado Innovation Limited's UK Patent Application No. 1410441.8, which is incorporated herein by reference, the storage system comprises a series of bins 10 which may further comprise delivery containers DT having customer orders contained therein, or which may further comprise bins 10 having stock items 28 waiting to be picked. These various bins 10 and combinations thereof may be stored within the storage system and accessed by the robotic load handling equipment 30 as described above.

[0032] In a first aspect of the present invention, the robotic picking and storage system described above with reference to Figures 1 to 4 comprises a robotic picking system, apparatus and method for enabling inventory items 28 to be picked on the storage system described above, thereby avoiding boxes 10 being transported to a pick station for manual or robotic picking of inventory items 28 to fulfill customer orders.

[0033] As shown in FIG. 5, a portion of the storage system 100 may be set aside for the express purpose of robotic on-grid picking. Any such area may have shipping containers DT located below a dedicated grid portion that is remote from the main portion of the system of framework 14 and grid 22, but linked to that main portion by an extension of grid 22 on which the robotic load handler 30 operates. The portion 100 of grid 22 may function as a dedicated robotic picking area. However, it will be understood that the main storage system may be used in the manner described below, so long as at least some shipping containers DT are located on top of at least some of the stacks 12 of boxes 10.

[0034] A plurality of robotic handling devices 30, for example as described above and in Ocado Innovation Limited's UK Patent Application No. 1413155.1, incorporated herein by reference, operate on the system of grid 22 and under the control of a separate centralized control utility, such as described in Ocado Innovation Limited's UK Patent Application No. 1509613.4, incorporated herein by reference.

[0035] In addition to the robotic load handling device 30, in accordance with the present invention, there are a number of additional similar looking robotic picking devices 130 that can be used to pick inventory items 28 from bins 10 and deposit the items directly into the shipping containers DT.

[0036] As shown in Figure 6a, one form of robotic picking apparatus 130 according to one embodiment of the present invention comprises a robotic picking means 50 within a cavity 40 in the body of the load handling apparatus 30. The external shape and configuration of the apparatus 130 substantially matches that of the load handling apparatus 30 so that it can operate on the grid 22 in the same manner. However, it will be appreciated that in this form of robotic picking apparatus 130, the picking means 50 occupies space previously used for the location of a box 10 being lifted from the stack 12. As will be explained below, the purpose of the robotic picking apparatus 130 is different from that of the load handling apparatus 30.

[0037] In one aspect of the invention, a robotic load handling device 30 is remotely instructed by a centralized control utility (not shown) to collect a bin 10 containing an inventory item 28 required for a customer order from a stack 12 in the main storage system. The load handling device 30 drops the bin 10 containing the inventory item 28 required for the customer order into an empty position in the robotic picking section 100 or into any other suitable position under the grid 22 of the storage system. A robotic picking device 130 is positioned above the dropped bin 10 containing the inventory item 28 by the centralized utility. Under remote control from the centralized utility, possibly assisted by on-board sensors, cameras and processing means, a robotic picking means 50 located in a cavity 40 of the picking device 130 is instructed to pick at least one inventory item 28 from the bin 10. The picked item is drawn into the cavity 40 of the robotic picking device 130. The picking device 130 is then moved to a position above the robotic picking portion of the system or any other portion of the storage system above the shipping container DT. The shipping container DT may comprise multiple bags 52 into which the inventory items 28 may be placed. Alternatively, the shipping container DT may comprise an empty shipping container DT. The robotic picking device 130 places the inventory items 28 within the shipping container DT or within the box 10 with the shipping container DT contained therein.

[0038] It will be appreciated that the shipping container DT may already comprise inventory items 28 that have been previously picked, either robotically or manually, on a grid or at a pick station, or manually picked at a pick station. It will be appreciated that the shipping container DT associated with a given customer order may be filled via multiple separate picking steps over a period of time. Furthermore, a customer order may comprise multiple shipping containers DT, and thus a shipping container DT in the picking portion of the system 100 may comprise only a portion of a customer order. Multiple shipping containers DT may be consolidated at a dispatch location just prior to the order being loaded onto a vehicle for delivery.

[0039] It will also be appreciated that this form of robotic picking device 130 occupies substantially a single grid space on the horizontal grid 22 of the framework 14. However, other forms of robotic picking device 130 may occupy more grid spaces. For example, the robotic picking device 130 may occupy a 2×1 grid space or a 2×2 grid space or more, as needed to perform the functions described.

[0040] Additionally, the robotic picking device 130 may include picking means 50 in forms other than those shown in Figures 6 and 7. Any suitable form of remotely or autonomously controllable picking means 50 may be used. It will be appreciated that the picking means 50 may have a variety of grippers or hands for picking the inventory items 28 from the bins 10. For example, the hands (not shown) may include suction cups actuated by vacuum means or may include remotely controllable grippers actuated by a central control utility.

[0041] The use of a robotic picking device 130 with a picking means 50 eliminates the need to transport boxes 10 from a stack 12 to a pick station (not shown), remove the required inventory item 28, and place the inventory item 28 in an assigned delivery container DT.

[0042] In a further embodiment of the invention with reference to Figures 6a and 6b, a robotic load handling device 130 may comprise a robotic picking device 130 as shown in Figure 6a. Such a robotic picking device 130 may comprise a picking means 50 within a cavity 40 in the body of the device 130. The picking means may comprise a robotic arm capable of being remotely or autonomously piloted such that inventory items 28 may be picked from and deposited into boxes 10 or shipping containers DT.

[0043] In use, and as shown in Figures 6a and 6b, such a robotic picking device 130 is positioned above a box 10 that is being transported or located within a picking portion of a storage system. The device 130 is used to quickly pick an inventory item 28 from the box 10 and deposit the inventory item 28 into a shipping container DT that is located adjacent to the box 10. As shown in Figures 6a and 6b, the inventory item 28 can be picked from the box 10 and deposited into the shipping container with relatively little movement of the picking device 130.

[0044] This method may also be used to consolidate customer orders in shipping containers DT located within a picking portion of the grid. For example, the robotic picking device 130 may be positioned above a first shipping container DT1 and the picking means 50 may be remotely operated to pick up an inventory item from the shipping container DT1. The robotic picking device 130 may then be moved into position above a second shipping container DT2 and the picking device may be operated to place it in the second shipping container DT2. This is particularly relevant for customer orders where large items are inefficiently stored in a shipping container DT and can be moved around to achieve a more efficient packing scheme for a given order.

[0045] This aspect of the invention may envisage the use of a robotic load handler, for example in the manner described in UK Patent Application No. 1410127.3, and such load handling apparatus is incorporated herein by reference.

[0046] This is advantageous when the delivery container DT is packed into a delivery vehicle for onward delivery to a customer, so that more efficient packing of the container DT can also result in more efficient packing into the delivery vehicle.

[0047] In the above method, it will be appreciated that it is advantageous to pick popular items from a single box 10 into multiple shipping containers DT. Using a robotic picking device 330 reduces congestion at manual pick stations, increasing throughput and reducing costs.

[0048] In a further aspect of the invention, the robotic picking and storage system described above with reference to Figures 1-4 includes various forms of robotic picking devices 130, 230, 330, 430.

[0049] As will be explained with reference to Figures 1 to 7, the above-mentioned robotic load handling devices 30 function cooperatively under the control of a suitable centralized control utility to remove boxes 10 from stacks 12 of the storage system. The function of each robotic handling device 30 is to collect and transport a box 10 containing a required inventory item 28 or items to a pick station from which the required inventory item 28 or items are loaded into a delivery container DT. It will be appreciated that the robotic load handling devices 30 may have additional functions such as removing boxes 10 from a stack 12, moving said boxes 10 to alternative positions within the stack 12 of boxes 10, and even periodically re-arranging the boxes 10 within the stack 12 in the form of housekeeping tasks.

[0050] In a further aspect of the invention, another derivative of the robotic load handling equipment 230 may include an alternative picking means 150 within the body of the equipment 230 that may be used to pick and lift inventory items 28 directly from storage bins 10 located within stacks 12 within the main portion of the storage system and transfer the inventory items 28 directly to a shipping container DT.

[0051] An alternative form of robotic picking device 230 is shown in Figure 8a. The picking device 230 in the following example is a 2x1 grid spacing device, however, it will be appreciated that alternative size devices 230 may be envisaged.

[0052] As can be seen in FIG. 8a, the robotic picking device 230 comprises a cavity 40, lifting means, a box gripper assembly 39 and a picking means 150. The lifting means together with the box gripper assembly 39 function to releasably attach to the box 10 so that it can be lifted from the stack 12 by the robotic picking device 230 in a manner similar to that described with reference to FIG. 3. The lifting means may take the form of a torpedo capable of engaging with a cooperating portion of the box 10. It will be understood that any suitable form of lifting means 44 may be used that is capable of engaging the robotic picking device 230 with the box and then raising it from its position into the stack 12 or into the picking area of ​​the system. The box 10 is held in the cavity 40 by a suitable holding means that is movable from a first position to allow the lifting means and box gripper assembly 39 to draw the box 10 into the cavity 40, to a second position in which the box 10 is held in place within the cavity 40 of the device 230.

[0053] The picking means 150 functions to pick an inventory item from the lifted box 10 into a cavity 40 in the picking device 230. The picking device 230 further comprises a moving means 48 for sliding the box 10 from a first position where it is located after lifting to a second position where it is located below the picking means 150. It will be appreciated that the moving means 48 may further function to hold the box 10 within the cavity 40.

[0054] In use, the lifting means 44 of the robotic picking device 230 is positioned above a box 10 in the stack 12 or picking area. The lifting means 44 and the box gripper assembly 39 together lift the box 10 into the cavity 40 of the device 230 as shown in Figures 8c and 8d. Once lifted, the box 10 is transferred by the moving means 48 from the first lifted position to an adjacent second position within the cavity 40 as shown in Figure 8e. It should be noted that the first position substantially corresponds to a first grid square 22 in the horizontal portion of the framework 14 and the second position substantially corresponds to a second grid square 22' adjacent the first grid square 22.

[0055] The picking means 150 is disposed above the second location in the cavity 40 of the device 230. The picking means 150 comprises suitable end means for locating and engaging at least one inventory item 28 from the bin 10 as shown in Fig. 9d. It will be appreciated that the picking means 150 comprises means for engaging inventory items 28 of multiple shapes or sizes. In practice, different engagement means may be required for picking different inventory items 28. Furthermore, the picking means 150 is required to be movable in at least x, y and z directions.

[0056] As shown in Figure 8f, once an inventory item is engaged by the picking means 150, the box 10 is moved from the second position to the first position by the moving means 48. The inventory item 28 is held on the picking means 150. The robotic picking device 230 is then moved to a position such that the second position within the device is above the target shipping container DT. The picking means 150 is then extended towards the shipping container DT identified as the one from which the inventory item needs to be picked, depending on the size and shape of the inventory item as required.

[0057] Once picked, the inventory item is placed into a shipping container DT, shown in FIG. 8f, positioned below cavity 40 in the second of the two grid spaces occupied by robotic picking device 230. However, it will be understood that robotic picking device 230 may be moved such that robotic picking device 230 is disposed above an alternative shipping container DT within robotic picking area 100 or on the primary storage system.

[0058] 8g, 8h, and 8i show an alternative method of robotic on-grid picking in which a shipping container DT is lifted into cavity 40 by robotic picking device 230 and inventory items 28 are placed into boxes 10 in a robotic picking area or in the main system.

[0059] It will be appreciated that in this alternative embodiment, the robotic picking device 230 may move on the grid 22 while carrying a shipping container DT, and the picking means 150 is used to pick inventory items from bins 10 in the storage system. In this manner, multiple inventory items may be picked into a single shipping container DT being carried by a single robotic picking device 230.

[0060] It will be appreciated that such a robotic picking device 230 may be used to retrieve boxes 10 from a main storage system where the required inventory items 28 have been located. Alternatively, the load handling device 30 may be used to lift boxes 10 from the main storage system and transport them to a dedicated robotic picking area 100 of the system, the dedicated picking area 100 having only a single layer of boxes 10 or shipping containers DT disposed within a framework 14.

[0061] The robotic picking device 230, under remote control from a centralized control utility and possibly assisted by on-board sensor cameras and processing means, is positioned above the boxes 10 dropped by the robotic load handling device 30 and functions as described above with reference to Figures 8g, 8h and 8i. The picked inventory items 28 are dropped off into the target shipping container DT in the dedicated part 100 of the storage system. It will be appreciated that means are provided on the robotic picking device 230, if necessary, for identifying the exact shipping container DT and, if appropriate, the exact location within the shipping container DT using remotely controlled automatic positioning means. In this way, the inventory items 28 are robotically picked from the boxes 10 and dropped off into the shipping container DT without the need for any boxes 10 or shipping containers DT to be transported to the pick station.

[0062] It will be appreciated that the robotic picking and handling equipment 230 may be of any size capable of transporting boxes 10 while accommodating the picking means 150. This may be feasible for the robotic picking equipment 230 if it is configured to have limited hoisting capabilities relative to other robotic load handling equipment 30 operating on the storage system. In this particular example, the picking and handling equipment 230 may only need to be equipped with telescoping grippers on two sides of a cavity within the body of the equipment 230.

[0063] Given that space within the robotic picking apparatus 230 is limited, an alternative robotic picking apparatus 430 is shown in Figures 9a-9f. In this robotic picking apparatus 430, the boxes 10 are not lifted into the cavity 40 of the apparatus 430 by lifting means 44 and box gripper assembly 39, but rather the boxes 10 are pushed up into the cavity 40 by lifting means 46 located at the bottom of the storage system. The lifting means 46 occupies grid space, for example as shown in Figure 9c.

[0064] The lifting means 46 comprises a substantially flat plate having locating pins 47 for cooperating with suitable cooperating means on the underside of the or each box 10 to stabilise the box 10 during lifting. The lifting means 46 may be lifted by any suitable means, such as via a hydraulically actuated piston which extends telescopically upwardly towards the grid.

[0065] In use, as shown in Figures 9b-9f, a robotic load handling device 30 (not shown in Figure 9b) retrieves a box 10 from the storage system and lowers said box 10 onto the lifting means 46. A robotic picking device 430 is moved to a position above the box 10 on the lifting means 46. The lifting means 46 is operated, for example by a central control utility, and the box 10 is lifted into the cavity 40 of the device 430. The device 430 comprises a releasable latching means 49 which functions to retain the box 10 in the cavity 40 during the picking process. The latching means 49 may comprise a moveable arm which is positioned below the box 10 once it is in place. Alternatively, the latching means 49 may comprise an electromagnetic catch operable by a solenoid or any other suitable means. It will be appreciated that any number of releasable latching mechanisms may be used which perform the required function of retaining the box 10 in the cavity 40.

[0066] Once the box 10 is in place, the picking means 150 may be used in a similar manner as described above with reference to the robotic picking device 230 above. That is, the picking means 150, which is movable in the xyz directions, is maneuvered under the control of a central control utility or any other suitable control means to a position above an inventory item 28 within the box 10. The picking means 150 is then lowered downwards to engage the inventory item 28. It will be appreciated that the picking means 150 comprises suitable gripping means for engaging the inventory item 28. Once engaged, the picking means 150 is lifted upwards and moved to a position above a shipping container DT located below a grid space adjacent the raised box 10.

[0067] Once the picking means 150, optionally assisted by sensor or camera means, is in the correct position above the required shipping container DT, the inventory item 28 is either released into the shipping container DT or placed into the shipping container DT by z-axis movement of the picking means 150.

[0068] It will be appreciated that the lifting means 46 may be used to lift a shipping container DT into the cavity 40 in the robotic picking device 430, and the picking means 150 is used to pick an inventory item 28 from a bin 10 located below the grid and place said inventory item in the shipping container DT within the cavity 40 of the picking device 430.

[0069] Once all required picking steps are completed, the robotic picking device 430 returns to the grid square above the lifting means 46, the lifting means 46 is raised and the box 10 or shipping container DT is unlatched from the device 430 and lowered down the grid space. The box 10 or shipping container DT is then positioned by the load handling equipment 30 in the required position where it awaits the next operation.

[0070] 10a-10d show a further embodiment of the robotic device 30. As can be seen in FIG. 10a, the robotic device 330 comprises a cavity 40 extending through the body of the robotic device 330. To achieve this, the lifting means 44, the box gripping mechanism 39, and all other mechanisms and electronics required to operate the robotic device 330 have been moved to the side of the device 330, thereby forming a robotic device with an overhang section. It will be understood that the overhang section shown in FIG. 10a and FIG. 10b is only an exemplary embodiment, and there may be only one overhang section disposed on one side of the robotic device. However, it should be noted that the cross-sectional area defined by the wheels of the device 330 only occupies the space of a single grid 22.

[0071] In use, a box 10 or shipping container DT may be lifted from the storage system into the extended cavity 40 of the robotic device 330. As shown in Fig. 10b, in this example, the shipping container DT is exposed at the top surface of the robotic device 330 when in home position. Thus, inventory items can be picked directly into the shipping container DT.

[0072] It will be appreciated that there are many ways to pick inventory items directly into a shipping container DT, and Figures 10c and 10d show two ways in which items can be picked directly into the robotic device 330 of Figures 10a and 10b.

[0073] In the embodiment of Figure 10c, a robotic picking vehicle 250 is suspended above the storage system. A number of robotic devices 330 containing boxes 10 with inventory items 28 needed to fulfill customer orders are positioned within reach of the robotic picking vehicle 250. The picking vehicle 250 can efficiently pick from boxes 10 located within the robotic devices 330 directly into a delivery container DT located within the central robotic device 330.

[0074] It will be appreciated that if the robotic picking vehicle 250 has sufficient reach, an inventory item 28 can be picked directly from a bin 10 located below the grid 22 of the storage system. It will be further appreciated that in this example, the robotic picking vehicle 250 can be suspended from the ceiling above the storage system at a fixed point. It will be appreciated that multiple robotic picking vehicles 250 can be suspended from the ceiling above the storage system.

[0075] Alternatively, a single picking device 250 may be placed on a movable beam that is movable in the XY directions above the storage system so that the single picking device 250 may be moved to desired points above the storage system under the control of a centralized control utility.

[0076] Additionally, it will be appreciated that the robotic picking vehicle 250 may be positioned around the edge of the storage system to allow for picking at the edge of the system.

[0077] In the embodiment of FIG. 10d, a further robotic picking device 550 is shown picking goods directly from one robotic device 330 with a box 10 into a robotic device 330 with a delivery container DT. The robotic picking device 550 is mounted on a form of robotic load handling device 630. It will be appreciated that the robotic picking device 630 does not have the ability to handle the box 10 or the delivery container DT, but rather is a means for moving the picking means 550 around the grid 22 above the storage system to a location where picking can occur. It will further be appreciated that the robotic picking device 550 mounted on the robotic load handling device 630 can be moved around the grid and used to pick inventory items from a box 10 at any location so long as the inventory items 28 are accessible to the picking means. For example, in one example, a box 10 can be lifted from one of the stacks 12 in the system and releasably latched to be disposed above the level of the grid. The mobile robotic picking device may then pick multiple inventory items 28 as required and deposit them individually or in combination into the target shipping container DT. The boxes 10 may then be returned to the appropriate stack 12. The latching means supporting the boxes 10 on the grid 22 may be of any suitable form capable of supporting the boxes 10 on the grid 22 and may be remotely operable.

[0078] It will be appreciated that an advantage of this aspect of the invention is that the boxes 10 and shipping containers DT are lifted once from the stack 12 and held within the robotic device 330. The boxes 10 and shipping containers DT do not need to be picked up from one location and temporarily positioned at an appropriate point in the system while the picking occurs. In this embodiment, a centralized control utility can position the boxes 10 and shipping containers DT in a device 330 that is in a relatively uncongested portion of the system. In this manner, the grid 22 can be used to its maximum capacity.

[0079] It will be appreciated that in any of the above described robotic picking devices, the picking means 50, 150, 250, 350, 450, 550, and 650 are described as picking a single inventory item 28 from a bin and placing the inventory item 28 in a shipping container DT. However, in a further aspect of the invention, the picking means 50, 150, 250, 350, 450, 550, and 650 may be configured to pick multiple inventory items 28, either picking multiple inventory items 28 from a single bin 10 or picking a single item 28 from multiple bins 10. The picked inventory items 28 may be for the same destination shipping container DT or may be for multiple shipping containers DT.

[0080] It will be appreciated that to enable the picking means 15 to pick multiple items from a single bin 10, the robotic picking apparatus described above may be provided with storage means within the cavity 40 of the apparatus.

[0081] In use, a robotic picking device as described above is moved to a position above a box 10 containing an inventory item 28 to be picked. In the situation where a customer has ordered more than one inventory item 28, the picking means 150 picks a first item 28 and places it in a storage means in the cavity 40. The picking means 150 is then maneuvered to pick a further inventory item 28 and place said second inventory item 28 in a storage means in the cavity 40 of the device. This is repeated until all required inventory items 28 are located in the storage means. The robotic picking device then moves to a position below the grid above a delivery container DT and the picking means is used to move the items 28 from the storage means into the delivery container DT, placing the items as required, assisted by suitable sensor or camera means as required.

[0082] In the case where multiple inventory items 28', 28'', and 28'' of different categories are to be placed in multiple bins 10, the robotic picking device is moved to a position above the first bin 10' and the first inventory item 28' is picked by the picking means and placed in a storage means in the cavity 40 of the device. The robotic picking device is then moved to a second bin 10'' in which a second inventory item 28'' is stored. The second item 28'' is then picked by the picking means and placed in a storage means in the cavity 40 of the device. Finally, the device is moved to a position above the third bin 10'''' and the third item 28''' is picked. The robotic picking device is then moved to a position above the target shipping container and the items 28', 28'', and 28''' are transferred by the picking means 150 from the storage means to the shipping container DT.

[0083] It will be appreciated that multiple inventory items 28 do not necessarily have to be for the same customer order and items 28 may be picked from multiple bins and therefore unloaded into multiple shipping containers DT.

[0084] This can be particularly useful where inventory items 28', 28'', and 28'' are located close together in the storage system.

[0085] Fig. 11a shows a further embodiment of the invention. As can be seen in Fig. 11a, the storage system or part thereof comprises a robotic picking means 350 located at one edge of the system. The robotic picking means 350 is movably mounted on a track means 360. The picking means 350 can be moved along the track under the control of a central utility. The robotic device 350 can be powered directly from a suitable fixed power source. Advantageously, in this embodiment of the invention, the robotic picking means 350 does not need to be battery powered and can be more rigid than the picking means 150 housed within a cavity of the robotic picking device. It will be appreciated that the robotic picking means 350 can be fixedly mounted to a suitable mounting means. The mounting means can include, but are not limited to, structural members of the building or facility housing the storage system, or application specific mounting means such as cross beams or RSJs.

[0086] In use, the robotic load handling device 30 positions a box 10 containing an inventory item 28 to be picked adjacent to the robotic picking device, and a shipping container DT that requires the inventory item 28 in the box 10 positioned by the robotic load handling device 30. Under the control of a centralized control utility, the picking means 350 picks the inventory item from the box 10 and places it in the target shipping container DT. The picking process continues in this manner until all shipping containers requiring said inventory item 28 have been addressed. At this point, the load handling device 30 may remove shipping containers DT that do not require further inventory items and move them to a dispatch area or into the storage portion of the main grid.

[0087] It will be appreciated that this grid picking method requires substantially fewer movements of the robotic device around the grid to pick inventory items.

[0088] Figure 12 shows an alternative configuration of the robotic picking apparatus 350 described above with reference to Figures 11a and 11b. In Figure 12, the robotic picking vehicle 450 is suspended from a gantry crane 480. The robotic picking vehicle 450 is suspended from suitable beams located around the outer edge of the grid 22. As shown in Figure 12a, the robotic picking vehicle 450 can pick from either boxes 10 or shipping containers located on the top of a stack 12 below the grid.

[0089] The picking means 450 operates in a similar manner to that described with reference to FIG. 11b, with the advantage that the entire grid 22 can be accessed.

[0090] If the removal of inventory items 28 from the shipping container 10 results in an empty shipping container DT, the shipping container DT may become a shipping container DT for another customer order or may be returned to storage or the goods arrival area so that additional inventory items 28 may be placed therein.

[0091] In this way, congestion at manual pick stations is avoided. Furthermore, pick stations, whether for manual or robotic picking, represent a significant investment cost. For items that can be picked effectively utilizing the present invention, the overall investment cost for a given picking capacity can be significantly reduced. It will be appreciated that some orders may be entirely pickable without access to a regular pick station.

[0092] Furthermore, it will be appreciated that by using a robotic picking area that is only one bin 10 deep, for example as shown in FIG. 5, it may be possible to increase the overall capacity of a given warehouse by making otherwise unused space productive.

[0093] Additionally, the robotic picking portion 100 of the storage and picking system may include a refrigerated or atmospheric section to allow picked orders to be held for a period of time before being loaded onto a delivery vehicle and dispatched. It will be appreciated that the grid size and average dwell time in the DT dispatch area is determined by the density of the robotic load handling equipment 30, 130 on the grid, so that shorter lead times may be acceptable, especially where low frequency items can also be manually picked at the pick station.

[0094] Furthermore, the above-described aspects of the present invention may be combined with a high speed stationary robotic load handling apparatus for certain inventory items 28 which are considered to be moving at high speeds, as previously disclosed in UK Patent Application No. 1502123.1 to Ocado Innovation Limited.

[0095] It will further be appreciated that the robotic picking devices 30, 130, 230, 330, and 430 may further comprise sensor means to ensure that the picked inventory item 28 is delivered to the correct shipping container DT and / or the correct part of the shipping container DT. The shipping container DT may comprise a number of bags and said sensor means may be used to ensure correct positioning of the inventory item 28 within the bag in the shipping container DT.

[0096] Although the above embodiments are described with reference to boxes 10 of substantially the same shape and configuration, it will be understood that the system may be adapted to use boxes and shipping containers of alternative shapes, sizes, and configurations. In this situation, robotic load handling and picking equipment must be provided in the system that can handle boxes and containers of various shapes and sizes. Additionally, certain areas of the storage system may be adapted to handle containers and boxes of alternative sizes.

[0097] It will further be appreciated that the picking means disposed above the grid 22 need not be a robotic device 30, but may comprise an operator having access to the grid 22 for picking the inventory items 28 directly from the boxes 10 for transfer to the delivery containers DT. The operator may travel on a robotic service device.

[0098] In a further aspect of the invention, the robotic picking and storage system described above with reference to Figures 1-4 includes a bin 10 that performs a variety of functions. It will be appreciated that the bin 10 described below may be used in conjunction with any of the robotic load handling equipment 30 described above.

[0099] In a further embodiment of the invention, a derivative 410 of the box 10 includes a mechanism for dispensing one or more of the multiple inventory items 28 from the bottom of the box 410. As shown in Figures 13-18, the box 410 may include a number of mechanisms for accomplishing this, each of which is described in detail below. However, it will be understood that the objective to be achieved in each case is substantially the same, namely the ability to either unload the inventory items 28 or to direct them into a shipping container DT located below the box 410, thereby avoiding the need for the box 10 containing the inventory items 28 to be transported to a pick station below the framework 14 of the storage system.

[0100] 13, a box 410 is shown having eight dispensers 56 disposed within a single box 410. It will be appreciated that the number of dispensers may vary depending on the size and shape of the inventory items 28 to be stored within the box 410.

[0101] The dispensers 56 disposed within the bins 410 of Figures 13a, 13b, and 13c comprise conventional vending machine mechanisms whereby a single inventory item 28 may be dispensed from a given dispenser 56. It will be appreciated that the stocked inventory items 28 may comprise a number of different items of a number of different categories within each bin 410. Alternatively, all dispensers within a single bin 410 may comprise the same inventory items 28.

[0102] In use, in response to an electrical, mechanical, or electromechanical input to the dispensing means, single or multiple inventory items 28 may be dispensed from the bottom of the dispensing means via an opening in the bottom of the box 410. The bottom of the dispensing means must cooperate with the bottom of the box 410 to ensure that the inventory items to be dispensed are released from the bottom of the box 410. It will be appreciated that the number of dispensing means disposed within each box will depend on the size of the inventory items 28 to be dispensed. It will further be appreciated that any given customer order may require multiple identical inventory items 28, and therefore the dispensing device must be capable of dispensing single or multiple inventory items 28 of a given type.

[0103] The opening at the bottom of the box 410 may be a flap, two cooperating flaps, a roll shutter, or any other suitable opening and closing means capable of remote or autonomous operation. It will be understood that the load handling equipment 30 transporting such a distribution box 410 may receive commands from a central utility to transport a dispenser type box to a given position above a delivery container DT in a robotic picking area. The robotic load handling equipment 30 may then comprise means for operating the distribution device in the box 410 so that the inventory items 28 are lowered into the delivery container DT that is lowered below the dispenser box 410. The commands received and transmitted via the robotic load handling equipment may be controlled via mechanical, electrical, electromechanical, or wireless means with suitable sensors disposed in the box 410 or the robotic load handling equipment 30 described above. These sensors may be located in the box gripper assembly 39 described above, although other suitable means may be used.

[0104] It will further be appreciated that the command can be given in a number of ways: for example, the command may be "go to location x and dispense upon arrival," or the command may be issued in two items, first "go to location x," and then "dispense."

[0105] Additionally, as shown in Figures 13a, 13b and 13c, the box 410 may include a permanent opening 58 at the bottom 58, and the dispensing means 56 functions to move and release the targeted inventory item 28 from the permanent opening 58.

[0106] It will be appreciated that the inventory items 28 packed in the cassettes in the dispenser box 410 may be identical or different. It will further be appreciated that any of the robotic picking devices described above can pick cassettes 56 from boxes 10 and organize the cassettes 56 into a single box, thereby creating a customized box 10, which can then be transported by an appropriate picking device to multiple shipping containers DT to dispense the required number of items 28. In this manner, the robotic picking device creates a customized box 10 such that the box can be transported around the system in the manner described above for depositing the inventory items 28 into the shipping container.

[0107] In use, in the storage, picking and dispatch system described above, such a distribution bin 410 may be used in a number of situations. First, arriving inventory items 28 may be unpacked and loaded into the distribution bin 410. Once loaded with the required inventory items 28, a robotic load handling apparatus of any of the types described above may be used to transport the distribution bin to the robotic picking portion of the storage system. However, it will be appreciated that the load handling apparatus 30 requires a means for actuating the distribution means 56 to lower the or each inventory item through an opening 58 in the bottom of the bin 410.

[0108] As shown in FIG. 14, once in position above a shipping container DT requiring an inventory item from the distribution bin 410, the distribution mechanism is actuated by suitable communication means between the robotic load handling equipment 30 and the distribution bin, and the required inventory item 28 is lowered into the shipping container DT located below the grid in the robotic picking portion of the storage system.

[0109] Once the inventory items 28 have been lowered into the required shipping containers DT, the distribution boxes 410 may be returned by the robotic load handling equipment 30 to the goods arrival portion of the system to be refilled, or may be returned to the main storage system for storage in stacks 12 until the inventory items 28 are needed again.

[0110] In this situation, the order in the shipping container DT may be completed. In that case, the container DT may be transported by the robotic load handling device 30 to a van or shipping station to proceed to delivery. However, if the order is not filled, the shipping container DT may be held in the robotic picking portion of the storage system to await additional inventory items 28 to be unloaded therein. Additionally, the shipping container DT may require transport to a conventional pick station so that additional inventory items 28 can be added, either manually or robotically. Additionally, if the order is completed but a delay occurs before shipping can occur, the shipping container DT may be transported to the main storage system and stored there until a delivery time is known.

[0111] In a further embodiment of the third aspect of the present invention, as shown in Figure 15a, the box 510 has one or more openings or hatches 60 at the bottom such that items contained therein can be dropped from the box 510 into a shipping container DT located below the box 510. In this manner, the box 510 may be considered a dispenser box 510 as described above. However, in this form of box 10, the entire contents of the box 510 are lowered into the shipping container DT when the box 510 is in its home position above the shipping container DT where it is required.

[0112] 15a, 15b, and 15c, preferably the entire bottom 75 is comprised of one or more movable panels 65. When the movable panel or panels are in the second fully open position shown in Figures 15a, 15b, and 13c, the hatch 60 spans the entire bottom 75 of the box 10. Having the hatch be the same size as the bottom of the box 510 ensures that even very large items can be dispensed into the shipping container DT below the box 510.

[0113] As shown in Figures 15a, 15b, and 15c, the slidable panel or panels move from a first, closed position, shown in Figure 15a, to a second, open position, shown in Figure 15b. In the first position, the panels 65 abut the sides of the box 10, as shown in Figure 15a, to form a continuous bottom.

[0114] This embodiment has the advantage that there is little risk of an item becoming stuck between the panel and the side 70 of the box 510. This embodiment has the further advantage that there is little or no risk of the slidable panel being obstructed by the contents of the box 510 or the contents of the shipping container DT below the box 510.

[0115] One form of mechanism for moving the panel 65 from a closed position to an open position is shown in Figure 15d, which comprises a roller type mechanism for rolling the panel 65 from an open position to a closed position as shown in Figure 15c.

[0116] In use, as shown in Figure 15e, the robotic load handling equipment 30 carries a dispenser box 510 in accordance with one aspect of the present invention and is moved into position above a target shipping container DT. The dispenser box 510 is actuated via a central control utility and / or via the robotic load handling equipment, and items stored within the box 510 are dropped through an opening in the bottom of the box 510 into the shipping container located below.

[0117] In another preferred embodiment as shown in Figures 16a and 16b, one or more slidable panels are provided as shown. In a first position, the panels abut or overlap each other or the sides 70 of the box 510 as shown in Figures 16a-16c to form a continuous bottom and close the hatch 60. In a second position, the one or more slidable panels may be independently opened, thereby allowing the contents of the box 510 directly above the actuated panel to be lowered into the shipping container DT below the robotic load handling equipment 30 transporting the box 510.

[0118] 16 may include inventory items 28 per movable panel as shown, or alternatively, there may be multiple items per panel and the panel may only be opened enough for a single item to be dispensed.

[0119] In a further embodiment of the dispenser box 510, as shown for example in Figures 17 and 16, the box 510 includes a hatch 60 that is releasably opened and closed by one or more movable panels or flaps 65. The panels may be flexible, resilient, deformable, continuous or discontinuous, or of any form suitable for moving from an open position to a closed position.

[0120] The panel can be moved between a first or closed position as shown and a second or open position in which the hatch 60 is fully or partially open under the control of the controller utility or load handling equipment 30.

[0121] In the preferred embodiment shown in FIG. 15, box 510 has sides 70a and 70b and a bottom 75 formed by a pair of pivotable panels or flaps 65a and 65b.

[0122] In the first, closed position, the flaps abut or overlap one another to form a continuous bottom 65 that retains the contents of the box 510, as shown in FIG.

[0123] In the second open position, the flaps 65a and 65b pivot and open outwardly towards the shipping container DT below the box 510 so that the contents of the box 510 can fall into the shipping container DT below the box 510.

[0124] The two or more pivotable panels 65a and 65b may be moved together or independently from a first position to a second open position by a controller utility in direct communication with the box 510 or through communication with a robotic load handling device 30 transporting the box 510 to dispense the contents of the box 510 into a shipping container DT beneath the box 510. The panels 65a and 65b may then be moved back to the first closed position such that the box 510 is available to receive another inventory item 28.

[0125] It will be appreciated that inwardly opening pivotable panels 65a and 65b may be provided.

[0126] It will be further appreciated that pivotable panels 65a and 65b may be provided that are capable of opening inwardly and outwardly.

[0127] In an alternative embodiment, box 510 may be divided into two or more compartments A and B, each with one or more pivotable panels 65 that can be independently moved from a first closed position to a second open position to dispense the contents of one of the compartments into the box below box 510A.

[0128] In an alternative embodiment, multiple abutting or overlapping panels form the bottom of the box 510 in the first closed position. The panels can be rotated by the controller to a second position to overlap, in the case of abutting panels, or to overlap further, in the case of overlapping panels, to form a hatch 60 through which items can be dispensed from the box 510 into a shipping container DT below the box 510. The size of the hatch can be changed by changing the amount of overlap of the panels in the second open position.

[0129] In an alternative embodiment, the hatch 60 extends only partially across the bottom 75. One or more movable panels 65 are provided which cover the hatch 60 and retain the contents of the box 510 in a first or closed position. The one or more panels 65 may be independently moved away from the hatch to a second position in which the hatch is partially or fully opened so that items within the box 510A fall through the hatch into a box below box 510A.

[0130] In a further embodiment, one or more panels 60 move laterally from a first position to a second position, it being understood that alternatively a single panel 60 that moves on both sides may be provided.

[0131] It will be appreciated that where more than one panel 60 is provided, the panels 60 may abut or overlap one another in the first position to close the hatch.

[0132] It will be appreciated that where more than one panel 65 is provided, each panel may be moved independently of the other panels.

[0133] It will be appreciated that multiple hatches may be provided, each closed at the bottom by one or more movable panels.

[0134] It will be appreciated that by changing the second position of one or more panels, the hatch may be partially or fully opened to dispense some or all of the contents of the box 510 into the shipping container DT below. This may be particularly preferred when small items are dispensed and larger items need to be held. Alternatively, this may be particularly preferred when dispensing fluids or free-flowing items such as, by way of example only, cereals, detergent, sugar or similar powders, packaging material or novelty items such as beads, confectionery, glitter, or small toys, or liquids.

[0135] It will be appreciated that a flexible or resilient layer may extend from the hatch to act as a funnel or channel for directing items towards the hatch.

[0136] It will be appreciated that in an alternative embodiment, the bottom of the box includes a resilient layer with an opening or valve through which heavier items can be dispensed. The opening may be sized so that the weight of the item to be dispensed is sufficient to send the item through the opening 60. Alternatively, the opening or openings may be sized and shaped to dispense items from the box 510 into the shipping container DT below the box 510 only if other items within the box 510 compress the item or items to be dispensed.

[0137] It will be appreciated that in an alternative embodiment, the bottom of the box is provided with a net so that small items fall through the box 510 into a shipping container below the box 510.

[0138] It will be appreciated that the dispenser box described in this embodiment may carry only a single item, however, the dispenser box 510 may carry multiple items, each located on a separately openable and closable portion of the bottom of the box, as shown in FIG.

[0139] In use, a robotic load handling device or robotic load picking device 30 as described in any of the embodiments above transports a distribution box 510 to a grid position on the robotic picking grid above a shipping container requiring the inventory items 28 in the dispenser box. A signal is applied to a releasable opening mechanism in the distribution box 510, or to the robotic load handling device carrying the box 510, which acts to release the opening mechanism in the distribution box and the inventory items 28 are lowered into the shipping container DT.

[0140] The dispenser box 510 may be equipped with verification means to verify that the dispensed items are unloaded into the correct shipping container DT or into the correct part of the correct shipping container DT.

[0141] In a further embodiment of the invention as shown in Figures 18a and 18b, box 10 is provided with a hopper configuration for containing "free-flowing" inventory items such as confectionery, liquids, flour, nuts, and bolts, or other such inventory items 28. Box 810 may be provided with separate hopper-type sections for containing different categories of inventory items 28, or box 910 may be provided with a single hopper-type unit for containing a single category of inventory items 28.

[0142] In use, a box 10 comprising the hopper-type dispenser box is transported by a robotic load handling or robotic load picking device 30 as described in any of the embodiments above. The device transports the distribution box 810, 910 to a grid position on the robotic picking grid above a shipping container DT requiring an inventory item 28 in the dispenser box 810, 910. A signal is applied to the releasable opening mechanism 61 in the distribution box 810, 910, or to the robotic load handling device carrying the box 810, 910, which acts to release the or each opening mechanism 61 in the distribution box, and the inventory item 28 is lowered into the shipping container DT.

[0143] It will be appreciated that in the case of the dispenser box 810, each section requires a releasable opening mechanism 61 so that the inventory items 28 can be dispensed into the correct section of the shipping container DT using sensor and camera means as appropriate.

[0144] It should be noted that the shipping container DT may be the actual shipping container for onward transport to a customer, or may be a box 10 with "to be picked later" items destined for delivery to another location, such as an alternative order fulfillment center. The term shipping container DT is used to distinguish the box 10 from the shipping container DT. However, it will be understood that the box and DT may be of similar or substantially identical shape and configuration, and that the function of the box dictates such definition, rather than any difference in the actual shape or size of the box.

[0145] It will also be appreciated that the shipping containers DT may be housed within boxes 10 to ensure that the robotic load handling equipment can handle all box movements whether within the stacks 12 of the main storage system or within the nominal robotic picking area.

[0146] Additionally, while many of the above embodiments are described with reference to a remote or separate robotic picking area, it will be appreciated that the main storage system can be used as a robotic picking area such that it functions simultaneously as a traditional picking and storage system.

Claims

1. A picking system for a storage system, the storage system comprising: a first set of parallel rails or tracks and a second set of parallel rails or tracks extending substantially perpendicular to the first set in a substantially horizontal plane to form a grid pattern having a plurality of grid spaces; a set of uprights supporting the track, the uprights and the track together defining a framework; a plurality of containers positioned below the truck and within the framework, a portion of the containers occupying a space below a grid space; The storage system further comprises a picking means disposed above at least one container, the container comprising inventory items; 13. A picking system comprising: a picking means adapted to pick at least one inventory item from said at least one container and to deposit the or each inventory item into at least one or more further containers.

2. 2. The picking system of claim 1, further comprising at least one robotic picking device operable on said parallel rails, said robotic picking device comprising said picking means.

3. 3. The picking system according to claim 2, wherein the picking means is disposed within the robot picking device.

4. 3. The picking system according to claim 2, wherein the picking means is disposed on the robot picking device.

5. 5. A picking system as claimed in any one of claims 1 to 4, characterized in that the storage system further comprises crane means, the crane means comprising at least one robotic picking means, the crane means being disposed above a grid of the storage system and the crane means being movable so that the or each picking means can be positioned above an individual container in the storage system.

6. 6. A picking system according to claim 1, wherein the picking means comprises at least one robotic picking device fixedly arranged on a structural member surrounding the storage system.

7. The picking system of claim 6 , wherein the structural member can include a ceiling, a wall, or a supporting frame structure of a building that contains the storage system.

8. 8. The picking system of claim 1, wherein the storage system further comprises at least one load handling device adapted to lift containers from below a grid and transport the containers to an alternative location within the storage system.

9. 9. A picking system as claimed in any one of claims 1 to 8, wherein a portion of the storage system comprises a picking area, the picking area comprising a section of a grid adapted to be one container deep below the grid.

10. The picking system of claim 8 , wherein the portion of the storage system comprises a plurality of containers for storing inventory items.

11. The picking system of claim 8 , wherein the portion of the storage system comprises a plurality of containers into which inventory items are transferred for onward delivery to customers.

12. The picking system of claim 10 , wherein the shipping container is disposed within a storage container.

13. 12. The picking system of claim 10 or 11, wherein the shipping container further comprises a plurality of bags arranged to contain the inventory items to be shipped.

14. 1. A method of picking inventory items from a storage system, the storage system comprising: a first set of parallel rails or tracks and a second set of parallel rails or tracks extending substantially perpendicular to the first set in a substantially horizontal plane to form a grid pattern having a plurality of grid spaces; a set of uprights supporting the track, the uprights and the track together defining a framework; a plurality of containers positioned below the truck and within the framework, each container occupying a space below a grid space; The method comprises: a. depositing at least one first container with a target inventory item to be picked; b. depositing at least one second container into which the target inventory items are unloaded; c. transferring at least one item from said at least one container to said at least one second container; and d. said items are transferred directly from said at least one container to said at least one second container by a picking means located on or above a grid.

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