Inventory Handling Station Assembly

Abstract

A connector (116) for connecting to at least three support elements of a three-dimensional modular structure, the connector (116) comprising a single body comprising: i) a first connector portion (118) for connecting support elements extending in a first direction; ii) a second connector portion (120) for connecting support elements extending in a second direction; and iii) a third connector portion (122) for connecting support elements extending in a third direction, wherein the first, second and third directions are substantially perpendicular to one another; and iv) one or more mounting projections (150 a, b), wherein each of the one or more mounting projections (150 a, b) has a substantially flat mating surface for mating with a corresponding mounting projection of an adjacent connector, each of the first, second and third connecting portions (118, 120, 122) comprising a contoured key (124) for controlling the orientation of the support elements in their respective first, second and third directions.

Description

[Technical field]

[0001] The present invention relates to the field of storage and retrieval systems for handling storage containers or bins stacked in a grid framework structure, and more particularly to an inventory handling station assembly for picking or supplying one or more items or goods to or from a storage and retrieval system comprising a grid framework structure. [Background technology]

[0002] Storage systems comprising a three-dimensional storage grid structure within which storage containers / receptacles are stacked on top of one another are well known. PCT Publication No. WO2021 / 175872A (Ocado) describes a known storage and fulfilment system in which a stack of receptacles or containers is arranged within a grid framework structure. The receptacles or containers are accessed by remotely operable load handling devices on tracks located on top of the grid framework structure. A system of this type is illustrated diagrammatically in Figures 1 to 3 of the accompanying drawings.

[0003] As shown in Figures 1 and 2, stackable containers known as receptacles or containers 10 are stacked on top of each other to form a stack 12. The stack 12 is arranged in a grid framework structure 14 in a warehousing or manufacturing environment. The grid framework is made up of a number of storage or grid columns 15. Each grid in the grid framework structure has at least one grid column for storing a stack of containers. Figure 1 is a schematic perspective view of the grid framework structure 14, and Figure 2 is a top view showing the stack 12 of receptacles 10 arranged within the framework structure 14. Each receptacle 10 typically holds a number of product items (not shown), which may be of different product types or may be the same depending on the application.

[0004] The grid framework structure 14 comprises a plurality of upright members or columns 16 that support horizontal members 18, 20. A first set of parallel horizontal grid members 18 are arranged at right angles to a second set of parallel horizontal grid 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 and are typically welded or bolted to one another, or a combination of both. The containers 10 are stacked between the members 16, 18, 20 of the grid framework structure 14 such that the grid framework structure 14 prevents horizontal movement of the stack 12 of containers 10 and guides vertical movement of the containers 10.

[0005] The top level of the grid framework structure 14 includes rails 22 arranged in a grid pattern across the top of the stacks 12. Referring also to FIG. 3, the rails 22 support a plurality of load handling devices 30. A first set 22a of parallel rails 22 guides movement of the robotic load handling device 30 in a first direction (e.g., X direction) across the top of the grid framework structure 14, and a second set 22b of parallel rails 22 arranged perpendicular to the first set 22a guides movement of the load handling device 30 in a second direction (e.g., Y direction) perpendicular to the first direction. In this manner, the rails 22 allow movement of the robotic load handling device 30 laterally in two dimensions in the horizontal XY plane, such that the load handling device 30 may be moved to a position above any stack 12.

[0006] A known load handling apparatus 30, shown in Figures 4 and 5, comprising a vehicle body 32 is described in PCT Patent Publication No. WO2015 / 019055 (Ocado), which is incorporated herein by reference, where each load handling apparatus 30 covers only one grid space of a grid framework structure 14. Here, the load handling apparatus 30 comprises a wheel assembly comprising a first set of wheels 34, consisting of a pair of wheels at the front of the vehicle body 32 and a pair of wheels 34 at the rear of the vehicle body 32, for engaging a first set of rails or tracks for guiding movement of the apparatus in a first direction, and a second set of wheels 36, consisting of a pair of wheels 36 on each side of the vehicle 32, for engaging a second set of rails or tracks for guiding movement of the apparatus in a second direction. Each set of wheels is driven to enable movement of the vehicle in the X and Y directions respectively along the rails. One or both sets of wheels can be moved vertically to lift each set of wheels off their respective rails, thereby allowing the vehicle to move in a desired direction.

[0007] The load handling apparatus 30 is equipped with a lifting device or crane mechanism for lifting the storage container from above. The crane mechanism comprises a winch, a tether or cable 38 wound on a spool or reel (not shown), and a grabber device 39. The lifting device or crane mechanism comprises a set of lifting tethers 38 (one tether near each of the four corners of the grabber device) extending vertically and connected near or at the four corners of a lifting frame 39, also known as a grabber device, for releasable connection to the storage container 10. The grabber device 39 is configured to releasably grip the top of the storage container 10 to lift the storage container 10 from a stack of containers in a storage system of the type shown in Figures 1 and 2.

[0008] The wheels 34, 36 are positioned around the periphery of a cavity or recess known as a container receiving recess 40 in the bottom of the load handling apparatus. As shown in Figures 5(a and b), the recess is sized to accommodate the container 10 when it is lifted by the crane mechanism. When in the recess, the container is lifted off the rails below so that the vehicle or load handling apparatus can move laterally to a different location. Upon reaching the target location, for example another stack, an access point in a storage system, or a conveyor belt, the receptacle or container can be lowered from the container receiving portion and released from the grabber apparatus.

[0009] Thus, upon receipt of a customer order, a load handling device operable to move on a track is instructed to pick up a storage container containing the items of the order from a stack in the grid framework structure and transport the storage container to an inventory handling station where the items can be removed from the storage container. When an inventory handling station is used to pick one or more items, such an inventory handling station is known as a pick station. Typically, the load handling device transports the storage container or container to a container lifting device integrated into the grid framework structure. A mechanism of the container lifting device lowers the storage container or container to the pick station. At the pick station, the items are removed from the storage container. Picking can be done manually or by a robot as taught in GB2524383 (Ocado Innovation Limited). After removal from the storage container, the storage container is transported to a second container lifting device where the storage container is lifted to grid level for removal by the load handling device and transported to its original location within the grid framework structure. A control and communication system tracks the location of the storage receptacles and their contents within the grid framework structure. Because the individual containers are stacked in vertical layers, their location in the grid framework structure or "hive" may be indicated using three-dimensional coordinates to represent the location of the load handling equipment or container and the depth of the container (e.g., (X,Y,Z), a container at depth W). Similarly, locations in the grid framework structure may be indicated in two dimensions to represent the location of the load handling equipment or container and the depth of the container (e.g., (X,Y), a container at depth Z). For example, Z=1 identifies the top layer of the grid, i.e., the layer immediately below the rail system, Z=2 is the second layer below the rail system, and so on down to the bottom layer of the bottom of the grid.

[0010] Similarly, when items are to be stored in a storage system or to replenish the inventory in the storage system, items delivered from a supplier are transported to an inventory handling station, known as a decanting station or a supplying station, as the items are supplied or decanted to replenish the stock in the storage system. Here, the items are removed from their packaging, registered with a unique stock-keeping unit, or SKU, depending on the type of item, and placed in a storage container at the decanting station. At the decanting station, the storage container is transported to a container lifting device, where the storage container is lifted to grid level for removal by a load handling device and transported to a location within the grid framework structure.

[0011] WO2017 / 211640 (Autostore Technology AS) describes a storage system for storing product items comprising a grid structure, where several storage containers are configured to be stored in vertical compartments within the grid structure, where each storage container is configured to contain at least one product item, the storage system comprising a picking and / or supply station, the storage system comprising a conveyor system configured to transport the storage containers from a first position to a second position and further to a third position. The conveyor system comprises a first tiltable conveyor configured to transport the storage containers from the first position through the second position to the third position. The picking and / or supply station is provided adjacent to the grid structure. The first and third positions are provided below two different vertical compartments in the grid structure. The tiltable conveyor comprises a hydraulic piston and cylinder mechanism for lowering and raising the conveyor. The tiltable conveyor supports the storage containers in an inclined position in the second position, thus allowing items to be manually picked from the storage containers. Once picked, the tiltable conveyor is tilted downward and the storage container is transported to a third position that allows the storage container to be removed by a load handling device operable on the grid structure.

[0012] WO2018 / 069282 (Autostore Technology AS) describes a picking / supply station assembly for a storage system with a grid structure. The picking / supply station assembly comprises a first container lifting device, a second container lifting device, and a picking / supply station, where the first container lifting device is disposable to receive storage containers from at least one vehicle at a top level of the grid structure and deliver the storage containers to the picking / supply station. The picking / supply station comprises a container transport assembly arranged to move the storage containers from the first container lifting device to the second container lifting device, where the second container lifting device is disposable to receive the storage containers from the container transport assembly and transport the storage containers to the top level of the grid structure. The container lifting device is arranged in the storage system to receive the storage containers from a vehicle or load handling device at the top level of the grid structure and transport the containers vertically downwards to a supply / picking station arranged on the first floor of a building in which the storage system is installed. In use, the first storage container is initially placed on the lifting arms at the top level of the grid and lowered towards the first conveyor unit. The spacing between the lifting arms is wide enough to allow the first conveyor unit to pass between them. During the pass, the first storage container will remain on the first conveyor unit while the lifting arms enter their lowest position. The first storage container is then transported by the first conveyor unit to exit the first lifting device. After the exit of the storage container from the first container lifting device, the lifting arms may return to the top level to retrieve the second storage container. The first and second container lifting devices are integrated into the grid framework structure, and thus the pick station forms an integral part of the grid framework structure.

[0013] A similar container lifting mechanism integrated into a grid framework structure for feeding a pick station is described in WO2020 / 074717 (Autostore Technology AS). WO2020 / 074717 (Autostore Technology AS) describes an access station for picking storage containers, the access station comprising a picking zone, with at least one conveyor arranged to transport the storage containers from an entry position through said picking zone to an exit position, the access station comprising at least one tilting device arranged to tilt the storage containers at least in the picking zone. Similar to the teaching in WO2017 / 211640 (Autostore Technology AS), the tilting device tilts the storage containers in the picking zone when the access station is to be operated by a picking worker, thereby providing the ergonomic benefits of tilting. The storage containers are received at an entry position located on an entry conveyor at the rear side of the access station. The entry location is configured for connection to another conveyor, for example a storage system conveyor, which transports the storage containers to and from the entry location. Upon entering the access station, the entry conveyor transports the storage containers in a transport direction via a tiltable access conveyor in a picking zone in front of the access station to an exit conveyor. Entry and exit of the storage containers into and out of the grid framework structure occurs via the rear of the access station. The entry and exit locations may each be connected to a storage system conveyor.

[0014] In a storage grid, the majority of the grid columns are storage columns, i.e. grid columns where storage containers are stored in stacks. However, the grid usually has at least one grid column that is not used for storing storage containers, but that comprises a location where a container handling vehicle may drop off and / or pick up a storage container, so that the storage container may be transported to a second location (not shown in the prior art figures) where the storage container may be accessed from outside the grid or transferred out or into the grid. In the art, such a location is usually called a "port" and the grid column where the port is located may be called a "distribution column". The storage grid comprises two distribution columns. The first distribution column may comprise, for example, a dedicated drop-off port where a container handling vehicle or a load handling vehicle may drop off a storage container to be transported through the distribution column and further to an access station or transfer station, and the second distribution column may comprise a dedicated pick-up port where a container handling vehicle may pick up a storage container that has been transported from the access station or transfer station through the second distribution column. The storage containers enter the access station via a first shipping column and exit the access station via a second shipping column.

[0015] No two storage and retrieval systems are the same since they must function in the environment in which they operate, such as the storage capacity, footprint size and layout of the grid framework structure. Thus, any peripheral units for decanting or retrieving items to and from the storage containers tend to be custom built. This includes the shape and arrangement of the inventory handling station components, such as the conveyor system, the inventory handling station framework structure, etc. Since the main function of the inventory handling station is to transport storage containers that are dropped off from drop-off ports in the grid framework structure to access or transfer stations where items can be picked from the storage containers, one of the main components of the inventory handling station that needs to be configured to suit the layout of the storage and retrieval system is the conveyor system. Depending on the transport direction of the storage containers, which are generally at the same level, the conveyor system typically comprises multiple adjacent conveyor units to provide a continuous transport surface from the drop-off / pick-up port to the access station where items can be picked or decanted from the storage containers. One or more of the plurality of conveyor units may be oriented to provide different transport directions for the storage containers. Examples of different orientations of the conveyor units include different transport directions for the storage containers as well as different orientations that transport the storage containers by their leading edge along the longest or narrowest edge of the storage container, also known as WEL (wide edge leading) or NEL (narrow edge leading) orientations.

[0016] There are many different configurations of conveyor units, including belt conveyor units, skate wheel conveyor units, and roller conveyor units, as well as different orientations or conveying directions of the conveyor system. In all of these different conveyor units, there are side walls on either side of the conveyor system, which define what is referred to herein as a "conveying channel." The side walls reduce the likelihood of items falling off the sides of the conveyor system. The side walls accomplish this by acting as a barrier to prevent items from moving laterally outward of the conveying channel relative to the longitudinal axis of the conveying system along which the items are intended to be conveyed. The side walls of the conveyor units are typically made of multiple side guards positioned adjacent to one another. Typically, the side guards are made of metal sheets, and often there are small gaps where the side guards meet between adjacent conveyor units.

[0017] Since the distance between the drop-off or pick-up port and the access or decant station may extend over multiple grid cells, it is essential that the items or storage containers being transported over the transport system are not damaged or deflected by any obstacles, particularly the side walls of adjacent transport units. In other words, there is a continuous transport channel from the drop-off / pick-up port and access station across multiple adjacent conveyor units with little damage, warping, or deflection of the storage container as it is transported on the transport system. To ensure that a continuous transport channel exists, it is essential that adjacent conveyor units are aligned to prevent any deviation of the storage container from its intended path along the transport system. As a result, multiple adjacent conveyor units are mounted on custom frame structures or support platforms that extend across the multiple conveyor units to minimize misalignment, thereby providing a continuous transport channel. In some cases, adjustments need to be made to one or more conveyor units to ensure alignment between adjacent conveyor units. Even when attempts are made to ensure that the transport units are aligned, there is still a problem of storage containers getting caught on the side walls of one or more of the conveyor units. To alleviate this problem, conveyor units of different lengths are sometimes utilized, with the longest length conveyor unit being used to carry the storage containers along the longest side of the inventory handling station, which is usually from the pick-up / drop-off port to the access station. As a result, inventory handling stations tend to be custom built with conveyor units of different lengths rather than the same, which adds a lot of cost and complexity to the design and assembly of the inventory handling stations. Summary of the Invention

[0018] The present invention has alleviated the above problems by modularizing the inventory handling stations so that different layouts and shapes of inventory handling stations can be built from a single type of module rather than having custom structures to fit the available footprint of the storage and retrieval system. In order to build a single type of module, it is paramount that adjacent modules can be assembled together with little or no adjustment in the alignment of the modules such that the conveyor units attached to the modules are aligned to provide a continuous conveyor channel. To provide a single type of module that can be assembled together, the present invention provides a connector for connecting to at least three support elements of a three-dimensional modular structure, the connector comprising: i) a first connector portion for connecting a support element extending in a first direction; ii) a second connector portion for connecting a support element extending in a second direction; and iii) a third connector portion for connecting a support element extending in a third direction, where the first, second and third directions are substantially perpendicular to each other; iv) one or more mounting projections, where each of the one or more mounting projections has a substantially flat mating surface for mating with a corresponding mounting projection of an adjacent connector; a single body comprising: The first, second and third connecting portions each include a contoured key for controlling the orientation of the support element in their respective first, second and third directions.

[0019] To ensure that adjacent modules can be assembled together, it is essential that the shape of the modular structures in the assembly is substantially regular, in the sense that adjacent modules are substantially equal in terms of the shape and / or size of the modular structures. Typically, the shape of the modular structures is a rectangular parallelepiped, so that multiple cuboid-shaped modules can be assembled together in any configuration to create different arrangements of inventory handling stations. The cuboid shape of the modular structures is largely controlled by the orientation of the support elements (also known as "struts") extending from the corners of the modular structures, and the ability of a given cuboid shape of the modular structures to be replicated among multiple modular structures in the assembly. If any one of the modular structures is not regular, this is reflected in the connections between adjacent modular structures in the assembly. For a regular cuboid shape, it is essential that the angles between the support elements at the corners of the structures are substantially 90°, i.e., the support elements extend along a Cartesian coordinate in three dimensions. To control the orientation of the support elements in the modular structure, the present invention provides a connector comprising first, second and third connector parts for connecting the support elements in first, second and third directions, respectively, the first, second and third directions being mutually perpendicular, i.e. along the x, y and z axes in a three-dimensional Cartesian system, where each of the first, second and third connecting parts comprises a contoured key for controlling the orientation of the support elements in their respective first, second and third directions. The contour of the key provides an indication of whether the support elements are correctly oriented. If any one of the support elements is not correctly oriented, this is reflected in the connection between the key and the support elements, since the contour of the key will prevent connection with the support element. The connector forms the corner of a cubic structure, so the connector functions as a corner piece of the modular structure.

[0020] In one example of controlling the orientation of the support element, the profile of the key comprises at least two opposing linear edges to prevent rotation of the support element about an axis extending through the key, each of the at least two opposing linear edges defining a load-bearing surface. Optionally, the profile of the key is substantially quadrilateral. To ensure that the support elements are substantially perpendicular to each other, preferably the keys of the first and second connector parts are in the same plane and are oriented such that lines extending through the midpoints of the keys of the first and second connector parts intersect at substantially 90°, where the keys of the third connector part are in a plane perpendicular to the plane of the keys of the first and second connector parts such that the connector has a line of symmetry extending through the keys of the third connector part. More specifically, the keys of the first connector part are mirror images of the keys of the second connector part with respect to the line of symmetry extending through the keys of the third connector part.

[0021] To enable the key to provide a load-bearing surface, the key preferably comprises a raised boss. To accommodate the support element, the raised boss comprises a substantially flat mating surface. Preferably, the raised boss comprises a hole, e.g. a threaded hole, to enable connection with the support element. To enable connectors from adjacent modular structures to butt up against one another when assembled together, the connector preferably further comprises one or more mounting projections having a substantially flat mating surface for mating with a corresponding one or more mounting projections of one or more adjacent connectors. Preferably, the one or more mounting projections comprise a first mounting projection lying in a first mounting projection plane and a second mounting projection lying in a second mounting projection plane, the first mounting projection plane being substantially perpendicular to the second mounting projection plane such that a line extending through the first mounting projection is substantially perpendicular to a line extending through the second mounting projection. Having connectors in which the first mounting projection and the second mounting projection lie in substantially perpendicular planes increases the flexibility of joining multiple modular structures from different sides of the modular structure. Preferably, the one or more mounting projections include a first hole and a second hole, the first hole being a threaded hole and the second hole being a non-threaded hole, for joining adjacent modular structures together in an assembly. To space adjacent modular structures in an assembly, particularly when multiple modular structures are arranged in a stack, the connector further includes a spacer for spacing adjacent connectors. Alternatively, the key includes a recess.

[0022] The present invention provides a modular structure comprising a plurality of vertically spaced modular sections, each of the plurality of modular sections comprising four connectors according to the present invention, each of the four connectors in a single modular section being connected to two other connectors by horizontal support elements to form a substantially rectangular frame, wherein each of the four connectors of vertically adjacent modular sections are connected together by substantially vertical support elements to form a frame structure, and a distal end of each of the horizontal and vertical support elements comprises an opening having a contour complementary to the contour of the connector's key such that the orientation of the horizontal and vertical support elements is controlled by the contour of the key. Alternatively, the distal end of each of the horizontal and vertical support elements comprises a raised boss having a contour complementary to the contour of the connector's key when the key comprises a recess.

[0023] One or more of the plurality of vertically spaced modular sections provide a support platform for mounting various components. If the modular structure forms part of an inventory handling station, one or more of the plurality of vertically spaced modular sections provide a platform for mounting a conveyor unit. To enhance the structural integrity of the modular structure, particularly from torsional forces, the connections between the horizontal and vertical support elements preferably further comprise angle brackets.

[0024] The present invention provides an assembly comprising a plurality of modular structures according to the invention, in which adjacent modular structures in the assembly are joined together by one or more of their respective attachment projections. Due to the connectors of the present invention allowing for control of the orientation of the support elements in substantially perpendicular directions, the resulting modular structures have a substantially cuboid shape allowing the assembly to be constructed in a regular cuboid structure, i.e. the modular structures represent building blocks or unit cells of the assembly. One or more attachment projections of the connectors allow the modular structures to connect to any of the sides of the cuboid structure. Due to the ability of the connectors to join with each other, different arrangements of modular structures can be assembled together. Optionally, the modular structures can be arranged in a stack. As an alternative or in addition to arranging the modular structures in a stack, the modular structures can be arranged side by side.

[0025] One example of the use of a connector according to the invention is to provide an inventory handling station for cooperating with a storage and retrieval system, the storage and retrieval system comprising: a plurality of upright columns arranged in one or more vertical planes to form a plurality of grid columns for stacking one or more containers between and vertically guided by the plurality of upright columns, the plurality of upright columns being interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members extending transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; the first and second sets of grid members respectively support first and second sets of tracks at an upper level of the grid framework structure for a load handling device to move one or more storage containers on the grid framework structure; The inventory handling station assembly comprises an assembly of modular structures according to the present invention arranged to support a transport system comprising a plurality of transport units, each of the plurality of transport units being attached to a respective modular section of an adjacent modular structure to form a continuous conveyor.

[0026] Having the ability to ensure that adjacent modular structures are aligned provides the advantage of ensuring that multiple conveyor units supported by the assembly are aligned to provide a continuous transport system. Optionally, the assembly of modular structures may include: i) a port station for receiving storage containers to be dropped off and picked up through the grid cells; ii) an access station that allows access to one or more storage containers dropped off from the port station; is arranged to support A transport system is arranged to transport storage containers between the port station and the access station.

[0027] The ability to stack multiple modular structures allows multiple modular structures to be assembled to form a vertical chute configurable to cooperate with at least one upright column, the at least one vertical chute having a first opening for receiving a storage container lowered by at least one load handling device through the grid cell and a second opening for allowing the container to exit the port station.

[0028] Optionally, the vertical chute comprises a container lifting device configured, in use, to lift the storage containers upwardly towards the grid structure so that the storage containers may be removed by at least one load handling device. Optionally, the port station comprises a feed zone for receiving storage containers dropped off through the grid cells, and a pick-up zone for picking up the storage containers through the grid cells. Optionally, the plurality of conveyor units comprises an entrance conveyor unit configured in the feed zone, an access conveyor unit arranged in the access station, and an exit conveyor unit arranged in the pick-up zone. Optionally, the entrance conveyor unit, the exit conveyor unit and the access conveyor unit are arranged to transport the storage containers in first, second and third transport directions, respectively, the first transport direction of the entrance conveyor unit being opposite and parallel to the second transport direction of the exit conveyor unit, and the third transport direction of the access conveyor unit being orthogonal to both the first transport direction of the entrance conveyor unit and the second transport direction of the exit conveyor unit. Optionally, the entrance conveyor unit, the exit conveyor unit and the access conveyor unit are arranged to convey the storage containers in first, second and third conveying directions, respectively, and the conveyor system is arranged such that a first conveying direction of the entrance conveyor unit is orthogonal to both a second conveying direction of the exit conveyor unit and a third conveying direction of the at least one access conveyor unit. Optionally, the port station and / or the access station comprise load cells.

[0029] The present invention further provides a fulfillment / decanting system comprising: i) a storage and retrieval system comprising a grid framework structure, the grid framework structure comprising: a plurality of upright columns arranged in one or more vertical planes to form a plurality of grid columns for stacking one or more containers between and vertically guided by the upright columns, the upright columns being interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members extending transversely to the first set of grid members in a substantially horizontal plane to form a grid or grid structure comprising a plurality of grid cells or grid spaces; a storage and retrieval system, the first and second sets of grid members supporting first and second sets of tracks, respectively, at an upper level of the grid framework structure for a robotic load handling device to move one or more storage containers on the grid framework structure; ii) one or more load handling devices remotely operated to move one or more containers stored on the grid framework structure, each of the one or more load handling devices comprising: i) a wheel assembly for guiding the load handling device on the grid structure; ii) a container receiving space located above the grid structure; and iii) a lifting device arranged to lift a single container from the stack into the container receiving space, iii) An inventory handling station according to the present invention, wherein said inventory handling station is configured to receive one or more storage containers from the storage and retrieval system.

[0030] Further features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments that proceeds with reference to the drawings. [Brief description of the drawings]

[0031] [Figure 1] FIG. 1 is a schematic diagram of a grid framework structure according to a known system. [Diagram 2] FIG. 2 is a schematic top view showing a stack of containers arranged within the framework structure of FIG. [Diagram 3] FIG. 3 is a schematic diagram of a known system of load handling equipment operating on a grid framework structure. [Figure 4] FIG. 4 is a schematic perspective view of a load handling apparatus showing a lifting device gripping a container from above. [Diagram 5] 5(a) and 5(b) are schematic perspective cutaway views of the load handling apparatus of FIG. 4, showing (a) a container receiving space of the load handling apparatus housing a container, and (b) the container receiving space of the load handling apparatus. [Figure 6] FIG. 6 is a top plan view of a fulfillment center incorporating a mezzanine level for housing inventory handling station assemblies, in accordance with an embodiment of the present invention. [Figure 7] FIG. 7 is a perspective front view of an inventory handling station assembly according to one embodiment of the present invention. [Figure 8] FIG. 8 is a top plan view of a conveyor system according to one embodiment of the present invention. [Figure 9] FIG. 9 is a top plan view of a conveyor system according to another embodiment of the present invention. [Figure 10] FIG. 10 is an exploded view of a modular structure in accordance with the present invention. [Figure 11] FIG. 11 is an exploded view of a corner section of the modular structure shown in FIG. [Figure 12] FIG. 12 is a perspective view of a corner piece according to the present invention. [Figure 13] FIG. 13 is a top plan view of the corner piece showing the orientation of the raised bosses to control the orientation of the support element. [Figure 14] FIG. 14 is a perspective view of the assembly of the modular structures supporting the transport system shown in FIG. 10 into an L-shaped configuration. [Figure 15]FIG. 15 is a top plan view of the corner piece showing the orientation of the attachment lugs for joining with adjacent corner pieces. [Figure 16] FIG. 16 is a perspective view of the juxtaposed corner pieces showing the mating of corresponding mounting projections. [Figure 17] FIG. 17 is a side view of the assembly shown in FIG. [Figure 18] FIG. 18 is a top plan view of the assembly of the modular structure shown in FIG. [Figure 19] FIG. 19 is a perspective view of a different arrangement of modular structures showing a stack of modular structures according to the present invention. [Figure 20] FIG. 20 is a perspective view of the mating of stacked corner pieces according to the present invention. [Figure 21] FIG. 21 is a perspective view of an assembly of a modular structure having a facing. [Figure 22] FIG. 22 is a perspective view of one example of a panel that may be used to sheathe the module structure shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] The present invention is devised in response to known features of storage systems, such as the grid framework structure and load handling equipment described above with reference to Figures 1-5. In a typical fulfillment center, a wide variety of items, such as grocery items, are stored in storage receptacles or containers, which are stored in one or more stacks in the grid framework structure, and more specifically, in grid columns. The grid columns are formed by a plurality of upright columns or vertical uprights arranged as vertical storage locations. Individual containers may be stacked in vertical tiers, and their locations in the grid framework structure or "hive" may be indicated using three-dimensional coordinates (e.g., (X,Y,Z), a container at depth W) to represent the location of the load handling equipment or container and the depth of the container. Similarly, the locations in the grid framework structure may be indicated in two dimensions (e.g., (X,Y), a container at depth Z) to represent the location of the load handling equipment or container and the depth of the container. For example, Z=1 identifies the top layer of the grid framework structure, i.e., the layer immediately below the rail or track system, Z=2 is the second layer below the rail system, and so on down to the very bottom layer of the grid framework structure. The majority of the grid columns in the grid framework structure are storage columns.

[0033] A typical order fulfillment system comprises a receptacle or container filling station, a storage and retrieval system, a number of order picking stations, an order container handling and sorting system, and dispatch equipment. Details of order fulfillment systems are described in PCT / IB2014 / 062165 (Ocado Innovation Limited), the details of which are incorporated herein by reference. In an order fulfillment system such as that described in PCT / IB2014 / 062165 (Ocado Innovation Limited), individual containers are stored within the storage and retrieval system and may contain one or more items, which may be identical. The storage and retrieval system comprises a grid framework structure in which storage receptacles or containers are stored in grid columns.

[0034] To pick an order with different items, it is often necessary to retrieve items from multiple storage containers. Such containers can be retrieved from the storage and retrieval system and transported to the desired order picking system. The specific containers required for the fulfillment of the order are accessed by a robotic load handling device operable on a grid framework structure. The robotic load handling device preferably comprises a control unit that receives control signals from a control system or a wireless communication unit of a central control system regarding information regarding where to pick up and deliver storage receptacles or containers in the grid framework structure. The control system controls the operation of one or more robotic load handling devices operable on the grid framework structure and comprises one or more processors, memory (e.g., read-only memory and random access memory), and a communication bus. The memory can be any storage device commonly known in the art, including, but not limited to, RAM, computer readable media, magnetic storage media, optical storage media, or other electronic storage media used to store data and that can be accessed by one or more processors.

[0035] At least one grid column of the grid framework structure is not used to store containers and typically comprises a location where a robotic load handling device may drop off and / or pick up a storage container or receptacle to and / or from a pick or supply station external to the grid framework structure. Within the art, such locations are typically referred to as "ports" and correspond to grid cells where storage containers or receptacles are dropped off or picked up. Depending on whether the port is located for drop-off or pick-up of storage containers, the grid column in which the port is located may be referred to as a "delivery column" located at the drop-off port and a "take-out column" located at the pick-up port. Separate areas are provided adjacent the grid framework structure to accommodate various stations including pick / decant stations such as service stations, charging stations, etc. Typically, the separate areas are provided by incorporating mezzanine levels supported by vertical beams between adjacent grid framework structures as shown in FIG. 6. The mezzanine level 104 provides, for example, a tunnel to accommodate the pick station and / or any one of the above-mentioned stations. FIG. 6 shows grid framework structures 14 on either side of the tunnel 102 created by the mezzanine 104 suitable for housing the inventory handling station assembly of the present invention. A grid or grid structure 22 from an adjacent grid framework structure extends across the top of the mezzanine 104 to connect to the grid 22 on either side of the mezzanine 104. For purposes of the present invention, a picking / replenishment station may be referred to as an inventory handling station assembly having an access station that can function as both a picking station and / or a replenishment station. One or more storage bins or containers 10 are stacked in grid columns 15a (first grid columns) on either side of the tunnel 102 created by the mezzanine 104. The grid columns vary in height depending on the number of storage receptacles or containers stacked in the grid columns.The inventory handling station assembly is located beneath grid columns 15b, 15c (second grid columns) that extend across the top of the mezzanine level 104, such that one or more of the grid columns 15b, 15c on the mezzanine level 104 represent drop-off port columns and pick-up port columns (see FIG. 7).

[0036] The inventory handling station assembly cooperates with the storage and retrieval system to provide a fulfillment system 100 for the fulfillment of one or more orders. A typical inventory handling station 60 as shown in FIG. 7 comprises one or more chutes 62 forming a supply zone 64, an access station 66, and one or more container lifting devices 68 forming a buffer zone 70. By reference to its name, the one or more chutes 62 enable a robotic load handling device operable on the grid framework structure 14b to lower a storage receptacle or container without any assistance from the one or more chutes 62. This may be done under the action of gravity, in which case the storage receptacle or container is allowed to descend the chute 62 by its own weight and / or is lowered by a lifting or hoisting mechanism of the load handling device.

[0037] One or more items are removed from or loaded into one or more storage receptacles or containers at the access station 66 depending on whether the access station 66 functions as a pick station or a replenishment station. The one or more chutes 62 and the one or more container lifting devices 68 are arranged to cooperate with the grid framework structure 14b described above. The grid framework structure 14b comprises a plurality of upright columns in one or more vertical planes and arranged to form a plurality of vertical locations or vertical grid columns 15 for allowing containers to be guided vertically by the plurality of upright columns. The plurality of vertical grid columns extend across the one or more chutes 62 and the one or more container lifting devices 68 of the inventory handling station assembly 60 (see FIG. 7). The plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members extending transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces. The plurality of grid cells are sized to allow storage containers to enter and exit the grid cells. The plurality of grid cells include drop-off and pick-up ports arranged to cooperate with one or more chutes 62 and one or more container lifting devices 68, respectively. More specifically, the grid columns in which the drop-off ports (delivery column 15b) and pick ports (removal column 15c) are located are arranged to cooperate with one or more chutes 62 and one or more container lifting devices 68, respectively, of the inventory handling station assembly 60.

[0038] The inventory handling station assembly of the present invention may be arranged as a stand-alone framework that divides the inventory handling station assembly into a feeding zone 64, a buffer zone 70, and an access station 66. One or more chutes 62 of the feeding zone 64 include at least two vertical guides that are receivable in the grid columns 15b of the grid framework structure and are positioned to guide storage receptacles or containers down the grid columns 15b through the drop-off ports and into the feeding zone 64. For the purposes of definition, the grid column in which the drop-off ports are located in the grid is referred to as the delivery column 15b. Similarly, the grid column in which the pick-up ports are located in the grid is referred to as the pick-up column 15c.

[0039] The conveyor system 76 transports the storage receptacles or containers from the supply zone 64 to the access station 66 and subsequently to the buffer zone 70 where the storage receptacles or containers are stacked vertically to be picked up by a load handling device operable on the grid framework structure 14b and returned to either its original destination in the grid framework structure or a new destination in the grid framework structure. In a particular embodiment of the invention, the conveyor system 76 comprises a plurality of conveyor units, namely an inlet conveyor unit 78, at least one access conveyor unit 80, and an outlet conveyor unit 82, and is arranged to transport the storage receptacles or containers from the supply zone 64 through the access station 66 to the buffer zone 70. The storage receptacles or containers are paused at the access station 66, which functions as a pick station or refill station. The conveyor units are arranged adjacent to each other or connected to each other such that the storage receptacles are transported from one conveyor unit to an adjacent conveyor unit as they proceed along the conveyor system 76.

[0040] The inlet conveyor unit 78 is disposed in the feed zone 64, more specifically, the inlet conveyor unit 78 is disposed in front of each of the one or more chutes 62. As shown in FIG. 7, the inlet conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 are at the same level. Similarly, the exit conveyor unit 82 is disposed in the buffer zone 70. Each conveyor unit may comprise any suitable arrangement of belt(s), chain(s), and / or rollers known in the art of conveyor systems. In the particular embodiment of the invention shown in FIG. 7, the inlet conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 comprise multiple roller conveyors for transporting storage receptacles or containers along a path on the conveyor system 76. As shown in FIG. 7, the conveyor system 76 is mounted on a roller frame. The inlet conveyor unit 78 and the exit conveyor unit 82 are disposed to accommodate a single storage receptacle thereon. Also shown in Figure 7 is an access station 66 comprising a work surface 86 above at least one access conveyor unit 80 and having an opening 88 allowing an operator to gain access to a storage receptacle or container on the at least one access conveyor unit 80 below. The path or conveying direction of the entrance conveyor unit 78 may be parallel and opposite to the path or conveying direction of the exit conveyor unit 82 such that the path or conveying direction of the at least one access conveyor unit 80 is perpendicular or orthogonal to the path or conveying direction of both the entrance conveyor unit 78 and the exit conveyor unit 82 (as shown in Figure 8). In other words, the storage receptacle or container follows a U-shaped path along the conveyor system 76 as shown in Figure 8, i.e., the storage receptacle changes direction twice along the conveyor system.At least one access conveyor unit 80 extends between the entrance conveyor unit 78 and the exit conveyor unit 82 and may comprise a plurality of conveyor units arranged adjacent to each other in a horizontal plane such that storage receptacles or containers are transported along the access conveyor unit 80 from one conveyor unit to an adjacent conveyor unit. Typically, at least one of the rollers of the access conveyor unit 80 and, optionally, the entrance conveyor unit 78 and / or the exit conveyor unit 82 are equipped with an integrated drive motor (not shown), while the remaining rollers may be connected to the drive rollers by belts (not shown) or may be passive. The shaded area 90 of the at least one access conveyor unit 80 is located below an opening 88 in the work surface 86 shown in FIG. 7. Optionally, as shown in Fig. 9, the path or conveying direction of the exit conveyor unit 82 extends longitudinally in the same conveying direction of the at least one access conveyor unit 80, i.e. the exit conveyor unit 82 is an extension of the at least one access conveyor unit 80. Here, the path or conveying direction of the entrance conveyor unit 78 is perpendicular or orthogonal to the path or conveying direction of both the at least one access conveyor unit 80 and the exit conveyor unit 82, such that the storage receptacle or container follows an L-shaped path along the conveyor system 76, i.e. changes direction once as the storage receptacle or container proceeds from the supply zone to the buffer zone.

[0041] FIG. 8 is an example where the leading edge of the storage container is the narrow end (NEL) of the storage container as it is conveyed across the inlet conveyor unit to at least one access conveyor unit 80. Optionally, the conveyor system may be arranged such that the path or conveying direction of the storage container may follow both U-shaped and L-shaped paths along the conveyor system 76. The combination of U-shaped and L-shaped paths allows multiple storage containers or containers to be queued in the buffer zone 70 before being lifted towards the grid for subsequent retrieval by load handling devices operable on tracks or rails on the grid. This allows multiple storage containers or containers to be processed through the access station 66 compared to prior art solutions. The combination of U-shaped and L-shaped paths allows a relatively small width of the inventory handling station assembly for processing multiple storage containers or containers at the access station 66 compared to prior art solutions.

[0042] An additional conveyor unit 84 (see Figures 8 and 9), positioned adjacent the entrance conveyor unit 78 and / or the exit conveyor unit 82, is integrated into the at least one access conveyor unit 80. In a particular embodiment of the invention, the additional conveyor unit or turning conveyor unit 84 comprises one or more rollers or belts or chains arranged to be driven transversely to the conveying direction (see arrows in Figures 8 and 9) of the at least one access conveyor unit, disposed laterally between or interdigitating between the rollers of the at least one access conveyor unit. The additional conveyor unit or turning conveyor unit 84 is lowered or raised by a lifting mechanism (not shown) relative to the rollers of the at least one access conveyor unit 80 so that in the raised position the turning conveyor unit 84 contacts the storage container and causes the turning conveyor unit 84 to drag or pull the storage container from the inlet conveyor unit 78 onto the at least one access conveyor unit 80. This is shown by the arrows in Figures 8 and 9.

[0043] An operator may pick or deliver a desired item(s) to or from a storage container at the access station 66 depending on whether the access station 66 functions as a pick station or a refill station. The access station may optionally include a weighing cell for measuring the weight of the items at the access station. If the at least one access conveyor unit 80 includes multiple conveyor units, an access conveyor unit 90 (shown by light shading in FIGS. 8 and 9 ) disposed below an opening 88 in the work surface 86 may be mounted on the weighing cell, or alternatively, the weighing cell may be positioned anywhere along the at least one access conveyor unit 80. The weighing cell is disposed below the at least one access conveyor unit 80 to weigh the storage container at the access station 66. The weighing cell may be a load cell or any other weighing cell commonly known in the art. A control panel (not shown) at the front of the access station 66 displays the weight of the storage container as items are picked from or loaded into the storage container. For example, when operated as a pick station, the weigh cell measures the weight of the storage container or container as one or more items are picked from the storage container. The storage control and communication system is used to monitor the inventory or stock of specific items by recording the weight of the storage container as items are picked from the storage container. This allows the storage control and communication system to track the contents of each of the storage containers or containers stored within the grid framework structure. If the contents of a particular storage container or container with a particular attribute or SKU are running low as measured by the weigh cell and recorded by the storage control and communication system, a notification is sent to an operator, for example, via the control panel, to refill the storage container.

[0044] To prevent one or more storage receptacles or containers from backing up at the access station 66, the buffer zone 70 includes one or more receptacle lifting devices 68 to allow one or more storage receptacles to be stacked vertically in the buffer zone 70. The receptacle lifting devices 68 include a lifting arm and a lifting mechanism. In a particular embodiment of the invention, the receptacle lifting devices 68 include a pair or two lifting arms 92. The space between the lifting arms 92 is wide enough to allow the exit conveyor unit 82 to pass between the lifting arms 92 as the lifting arms 92 descend past the exit conveyor unit 82. In use, the lifting arms 92 descend to a bottom level below the exit conveyor unit 82 such that the lifting arms 92 may engage a bottom wall of a storage receptacle on the exit conveyor unit. The storage receptacle or container is lifted from a bottom position on the exit conveyor unit 82 to a top position toward the grid framework structure 14b such that the storage receptacle is vertically spaced from the exit conveyor unit 82. This allows the second storage receptacle or container to enter the exit conveyor unit 82 and be stacked vertically below the storage receptacle or container above. The storage receptacle in the top position waits until a load handling device operable on the grid at the upper level can remove the storage receptacle or container through the pick-up port via the removal column 15c. More specifically, a grabber device of the load handling device can grab the storage receptacle or container at the top level and lift it into a container receiving space of the load handling device. A sensor detects the removal of the storage receptacle at the top level, which sends a signal to the control system or controller to lower the lifting arm 92 below the second storage receptacle or container resting on the exit conveyor unit 82, which is subsequently lifted to the top level, allowing a third storage receptacle or container queued in the buffer zone to enter the buffer zone 70 via the exit conveyor unit 82.Once the storage receptacle or container enters buffer zone 70, the entire process is repeated.

[0045] The container lifting device 68 may include multiple pairs of vertically spaced lifting arms 92 to allow multiple storage containers to be vertically stacked at different heights in the buffer zone 70. For example, a first pair of lifting arms may be positioned to lift a first storage container to a first height, a second pair of lifting arms may be positioned to lift a second storage container to a second height, and so on. This allows multiple storage containers to be vertically stacked at different heights in the buffer zone 70. In addition, one or more container lifting devices 68 may be positioned adjacent to each other. To conserve space and reduce the footprint of the inventory handling station assembly 60, a first container lifting device may be positioned at an end of at least one access conveyor unit 80 such that a storage container or container may be transported to the first container lifting device along the same path of the access conveyor unit 80. When the first container lifting device becomes full, the storage container can be commanded to divert to the adjacent second container lifting device, for example, in a direction perpendicular to the conveying direction of at least one access conveyor unit. This can be achieved by controlling the diversion conveyor unit 84 adjacent to the buffer zone 70 to convey the storage container to the second container lifting device. Here, the control system or a separate controller monitors the occupancy status of the first container lifting device and the second container lifting device, and depending on the occupancy status of the lifting devices, decides whether the storage container should be conveyed to the first container lifting device or the second container lifting device. The occupancy status of the container lifting device 68 is determined by one or more sensors to detect the presence of the storage container or container at the container lifting device. Examples of sensors include, but are not limited to, proximity sensors, such as optical sensors.

[0046] One of the main criteria of the transport system 76 is to ensure that storage containers or items transported along its conveyor channel reach their intended destination without the possibility of falling off the side of the transport system 76. While attempts have been made to reduce the possibility of items or storage containers falling off the side of the transport system by installing side walls or barriers on both sides of the transport system, there is still a problem of one or more of the conveyor units being misaligned, causing one or more items or storage containers to get stuck and cause a blockage in the transport system. This is especially true when adjacent conveyor units in the transport system are not perfectly aligned, causing one or more items or storage containers to deviate from their intended path on the transport system. It is therefore essential that adjacent conveyor units are perfectly aligned to mitigate deviation of the transported items or storage containers from their intended path on the transport system. To reduce the possibility of misalignment, multiple conveyor units are typically mounted on a custom-made conveyor frame or base structure that extends across multiple grid cells. The custom conveyor frames are generally of one piece construction, thus minimizing any chance of misalignment of the conveyor units. Similarly, the length of the conveyor units in the conveyor system varies to accommodate different transport lengths of the conveyor system. For example, the length of at least one access conveyor unit 80 in Figures 8 and 9 can be a single elongated conveyor unit that extends across multiple grid cells between the delivery column 15b and the retrieval column 15c, rather than a series of separate joined short conveyor units. As a result, no two inventory handling stations are the same, as they tend to have custom conveyor systems that rely on available space in the storage and retrieval system to capture storage containers that are dropped off of the grid structure.

[0047] The present invention alleviates the above problems by modularizing the inventory handling station so that the inventory handling station can be constructed from a regular arrangement of modules or modular structures 110, where each modular structure 110 forms a unit cell of the inventory handling station. The pattern of the inventory handling station is dictated by the arrangement of the modular structures. To form an inventory handling station from an assembly of modular structures 110, each of the modular structures is substantially identical in terms of shape and size. The repeating pattern of modular structures can then be assembled into a frame or support structure for supporting the different components of the inventory handling station described above, such as the conveying system. When assembled together, the assembly provides a substantially aligned frame for aligning and supporting a plurality of conveyor units. In a particular embodiment of the present invention, shown in the exploded view of a single modular structure 110 in FIG. 10, the single modular structure 110 has a cubic-like frame structure formed from a plurality of horizontal support elements or columns 112a, 112b and vertical support elements or columns 114 connected at the corners by connectors 116. To ensure that the modular structure 110 has a regular cubic structure, the horizontal support elements 112a, 112b and the vertical support elements 114 at the corners of the modular structure must be substantially perpendicular to each other. The basic building block of a cubic modular structure has eight exterior corners and twelve support elements, four of which are vertical and eight of which are horizontal. In a particular embodiment of the invention shown in FIG. 10, the geometry of the modular structure has a rectangular cubic structure with all of the corners being substantially perpendicular and the opposing edges of the cubic structure being equal. The angles that the support elements make at the corners of the modular structure are controlled by the connectors 116. For purposes of definition and because the connectors form the corners of the modular structure, the connectors may be broadly defined as corner pieces 116.

[0048] The particular example of a modular structure according to the invention shown in Figure 10 can be broken down into a plurality of vertically spaced modular sections 117, each of which provides a mounting for supporting a component unit of an inventory handling station, such as a conveyor unit. Each of the plurality of modular sections 117 is assembled from four corner pieces 116, each of which in a single modular section 117 is connected to two other corner pieces 116 by horizontal support elements or struts 112a, 112b to form a substantially rectangular frame lying in a substantially horizontal plane (see Figure 11). Each of the plurality of modular sections 117 is vertically spaced apart to form a cube-like structure by connecting each of the four corner pieces 116 of vertically adjacent modular sections 117 together by vertical support elements or struts 114.

[0049] To ensure that the support elements 112a, 112b, 114 are substantially perpendicular to one another at the corners of the modular structure, the connectors or corner pieces 116 have keying in features 124 that control the orientation of the support elements. In this application, the terms "keying in" and "key" are used interchangeably. In the case of a cubic structure, the keying in features control the orientation of the support elements perpendicular to one another in the horizontal and vertical planes, i.e., in the x, y, and z directions of a Cartesian coordinate system. One example of a corner piece 116 according to the present invention is shown in Figures 11-13 and comprises a first connecting portion 118, a second connecting portion 120 and a third connecting portion 122 for connecting to support elements 112a, 112b, 114 such that the first connecting portion 118, the second connecting portion 120 and the third connecting portion 122 extend in first, second and third directions, the first, second and third directions being mutually perpendicular, i.e., in the x, y and z directions of a Cartesian coordinate system. To control the orientation of the support elements in the first, second and third directions, keying-in features 124 in each of the first, second and third connecting portions 118, 120, 122 are contoured to control the orientation of the support elements 118, 120, 122 in their respective first, second and third directions. The keying-in features 124 should not only be capable of controlling the orientation of the support elements 112a, 112b, 114, but should also be capable of providing a load-bearing surface 126 to resist distortion of the cubical shape of the modular structure 110. In certain embodiments of the invention, this is provided by raised or protruding bosses 124 that are contoured to provide a load-bearing surface 126 to prevent movement of the support elements 112a, 112b, 114 in their respective horizontal or vertical planes.

[0050] In order to limit the movement of the support elements 112a, 112b, 114 when attached to the raised boss 124, the connection ends 128 of the support elements 112a, 112b, 114 are provided with openings 130 that are contoured to seat on the raised boss 124 in a specific orientation. In particular, the contour of the openings 130 at the connection ends 128 of the support elements 112a, 112b, 114 is made to close tolerances such that the size of the openings 130 is slightly larger than the size of the raised boss 124 to allow the raised boss to be received in an interference fit within the openings of the connection ends of the support elements. An example is shown in FIG. 11 where the openings at the connection ends of the support elements are provided to the raised bosses of the first, second and third connection parts of the connector. The contour of the openings 130 has a shape that corresponds to the shape of the contour of the raised boss 124 so that there is only one orientation in which the support elements can connect to the corner piece 116. The contour of the raised boss 124 thereby dictates the orientation of the support elements 112a, 112b, 114 and prevents connection to the raised boss 124 if the orientation differs from that dictated by the raised boss. There are a number of scenarios when the connection ends 128 of the support elements 112a, 112b, 114 are prevented from engaging with the raised boss 124 of the corner piece 116. For example, the lengths of the opposing support elements are not substantially equal, causing distortion of the cuboid shape of the modular structure and / or the support elements are provided incorrectly to the corner piece. In the particular embodiment shown in FIG. 11, the raised boss 124 has a substantially rectangular contour providing at least two opposing straight edges configured to be received with an interference fit within correspondingly shaped openings 130 in the connection ends of the support elements.

[0051] To produce the contour of the opening 130 of the support elements 112a, 112b, 114 with close tolerances, the opening 130 is preferably machined into the support elements. One example of machining the opening at the connection end of the support elements with close tolerances is using laser cutting, but other forms of precisely cutting the opening in the support elements are also applicable in the present invention. The support elements 112a, 112b, 114 are shown as angled beams to provide the necessary bending stiffness when mounting the component units to the module section 117, but other cross-sectional shapes of the support elements, e.g., I-shaped, U-shaped, having the necessary bending stiffness to support components such as conveyor units, are also applicable in the present invention. The support elements may include one or more attachment points 132 for fastening different types of component units. In a specific embodiment of the present invention, the one or more attachment points 132 include one or more mounting holes for receiving bolts or screws or other fastener types.

[0052] The geometry and / or contour of the raised boss is tightly controlled so that the support elements connected to the raised boss are substantially perpendicular to each other. Thus, lines 134, 136 extending along the midpoints of the raised bosses 124 of the first connecting portion 118 and the second connecting portion 120 in a horizontal plane intersect at substantially 90°. To allow the corner piece 116 to be rotated 90° so that the same type of corner piece can be used to connect the support elements 112a, 112b, 114 at different corners of the modular structure 110, the corner piece 116 has a line of symmetry 138 extending through the raised boss 124 of the third connector portion 122 in a vertical plane. The intersecting lines 134, 136 and the line of symmetry 138 are shown in dashed lines in FIG. 13 . One way to tightly control the contour of the raised boss 124 so that the raised boss precisely engages with the opening in the support element is to machine the contour from a single body so that the corner piece is formed as a single piece of material. For example, the corner piece 116 can be machined from a single piece of metal, such as aluminum. However, other molding methods and / or materials for making the corner piece are applicable in the present invention so that the tolerance of the contour of the raised boss is tightly controlled. For example, the use of additive manufacturing and / or the use of plastic materials can be alternative manufacturing methods or materials for forming a corner piece with a raised boss whose contour is tightly controlled.

[0053] Each of the raised bosses 124 has a substantially flat mating surface that provides a contact surface for contacting a support element. To fasten or secure the support elements 112a, 112b, 114 once attached to the corner piece 116, the raised bosses 124 may include threaded holes 140 for receiving threaded bolts 142, as shown in FIG. 11. To assemble the modular structure, the horizontal support elements 112a, 112b and the vertical support elements 114 are provided up to the corner piece 116 so that the raised bosses are received in openings in the connection ends 128 of the support elements 112a, 112b, 114, as shown in FIG. 11. Tight tolerances on the contours of the raised bosses ensure that the support elements are oriented in the correct direction. In the case of a cubic structure, any mismatch in length or shape of opposing support elements will be manifested in the failure of the raised bosses to be received in the openings of the support elements. More specifically, the separation between the openings 130 at the distal end of a given support element for opposing support elements is substantially equal. The closer the angle between the support elements at the corners is to 90°, the greater the ability for the corner pieces at each of the corners to be able to key to the support elements.

[0054] All substantially equal, the support elements can be connected to the corner pieces such that the support elements are oriented in a substantially perpendicular direction at each of the corners of the modular structure, with the resulting modular structure adopting a substantially cubical shape. To prevent distortion of the modular structure and to increase the structural rigidity of the modular structure, stiffeners or angle brackets 144 can be used to support the horizontal support elements against the vertical support elements (see FIG. 10). One or more of the modular sections 117 can support a platform 146 (see FIG. 10) to provide a support surface and / or increase the torsional rigidity of the modular structure. The platform 146 is shown in FIG. 10 and is connected to the horizontal and vertical support elements in a single modular section 117 to stiffen the modular structure in the X and Y directions.

[0055] Because the angles at the corners of the modular structures are substantially right angles and the opposing edges are substantially equal, the resulting modular structures can be assembled with other similar or similar modular structures in a repeatable or regular pattern with little risk of misalignment between adjacent modular structures. This is important when the assembly forms an inventory handling station that supports a transport system from a drop-off or pick-up port to an access station as described above. An example of an assembly of modular structures 148 according to the present invention for use in an inventory handling station is shown in FIG. 14. Each of the modular structures 110 serves as a unit cell in the assembly 148 that is regularly repeated to form various patterns. Different arrangements of modular structures 110 can be assembled together to form various patterns that occupy different footprints. In FIG. 14, the modular structures 110 are arranged side-by-side in an L-shaped pattern or configuration. In addition to or in addition to placing the modular structures side-by-side, the modular structures can be stacked on top of each other. When the assembly is used as an inventory handling station, the stack of modular structures provides chutes that cooperate with ports in the grid structure to form either a drop-off chute (delivery column) or a pick-up chute (removal column) in the feed zone or buffer zone, respectively, as described above. When the chute functions as a pick-up chute to form a pick-up column as described above, one or more of the modular structures may optionally be provided with one or more container lifting devices as described above.

[0056] To facilitate joining adjacent modular structures 110 together, the corner pieces 116 at the corners of the modular structures 110 are provided with one or more mounting projections 150a, 150b, each of which has a flat mating surface that butts against a corresponding mounting projection of a corner piece in an adjacent modular structure. In a particular embodiment of the invention shown in FIG. 15, the corner piece 116 is provided with a first mounting projection 150a and a second mounting projection 150b that lie in their respective vertical planes that are substantially perpendicular to each other. Each of the first mounting projection 150a and the second mounting projection 150b are provided with a mating surface that lies in their respective vertical planes so that they can butt against a corresponding mating surface of an adjacent corner piece. A top plan view of mating corner pieces from adjacent modular structures is shown in FIG. As shown in the side view of the assembly of the modular structures shown in FIG. 17, when adjacent modular structures are brought together side by side, the mating surfaces of the first and second mounting projections 150a, 150b of the corner pieces 116 from adjacent modular structures 110 are brought together in abutting relation to each other as shown in FIG. 16, so that their respective mating surfaces are ultimately in the same or common vertical plane. To secure the adjacent corner pieces together, each of the first and second mounting projections includes at least one hole for receiving a bolt or pin. The at least one hole can be a blind hole or a through hole. In a particular embodiment of the invention clearly shown in FIG. 12, each of the first and second mounting projections 150a, 150b includes a first hole 152 and a second hole 154, at least one of the first hole 152 and the second hole 154 having a threaded inner wall for threaded engagement with a bolt or screw. Having a threaded inner wall in one of the first hole 152 or the second hole 154 and a non-threaded inner wall in the other hole has the advantage of aiding in assembling adjacent modular structures together. Due to the symmetry of the corner pieces of the present invention, which allows the corner pieces to be rotated 90 degrees, when the corner pieces are brought together from adjacent modular structures in an assembly such that their corresponding mating surfaces contact (see FIG. 17), the non-threaded hole will always be adjacent to a threaded hole.When the holes are through holes, a non-threaded hole adjacent to the threaded hole allows a threaded bolt to be driven into the non-threaded hole first so that the threads of the bolt will eventually engage the threads of the hole in the adjacent corner piece.

[0057] Assembling a plurality of modular structures involves fitting separate modular structures together such that adjacent modular structures in the assembly are juxtaposed side-by-side (see FIG. 17). When each of the modular structures is substantially cubic, holes in corresponding first or second mounting lugs of adjacent corner pieces at the corners of the modular structures are aligned in the assembly to receive bolts. Adjacent modular structures in the assembly are secured together by threading bolts through holes in the mounting lugs of the adjacent corner pieces. Additional modular structures may simply be bolted onto an existing assembly to change the shape or footprint of the assembly. Finally, the assembly comprises a regular or repeated arrangement of modular structures, each modular structure forming a unit cell in the assembly. Due to the modular nature of the inventory handling station, multiple modular structures may be assembled together in a variety of patterns.

[0058] The uniformity of shape and size of each of the modular structures, afforded by the ability of the corner pieces of the present invention to connect the support elements in a substantially perpendicular direction, improves the ability to align adjacent modular structures with one another in an assembly. This is most important when the assembly supports a transport system comprising multiple adjacent conveyor units, as it is essential that items or storage containers carried by the transport system do not get caught on the side walls of the transport system as a result of misalignment of adjacent conveyor units. In the particular example shown in the top view of the assembly shown in FIG. 18, the transport system 76 comprises multiple conveyor units arranged in an L-shaped pattern incorporating an inlet conveyor unit 78, an outlet conveyor unit 82, and at least one access conveyor unit 80 between the inlet conveyor unit 78 and the outlet conveyor unit 82. Various other patterns of transport systems are permissible in the present invention and are highly dependent on the arrangement of the modular structures.

[0059] To form a vertical chute for cooperation with a port column to drop off one or more storage containers onto a transport system for transport to an access station or to pick up one or more storage containers leaving an access station into a buffer zone as described above, a plurality of modular structures 110 may be stacked on another modular structure to form a vertical column. In addition to assembling modular structures of the present invention side-by-side (see Figs. 17 and 18), the corner pieces 116 of the present invention allow the modular structures to be stacked in a three-level stack as shown in Fig. 19. Compared to the attachment protrusions for joining modular structures side-by-side, the corner pieces optionally include spacers 156 to space adjacent modular structures in a stack. In the particular embodiment of the present invention shown in Fig. 20, the spacers 156 have a frustoconical shape, but other shapes for spacing adjacent corner pieces in a stack are also applicable in the present invention. The frustoconical shape has flat mating surfaces for butting against the spacers of adjacent corner pieces in a stack as shown in Fig. 20. The spacers 156 include holes 158 that allow adjacent modular structures to be secured to one another via their respective corner pieces. The spacers 156 also provide mountings for securing legs 160 to the assembly, as shown in Figures 14 and 17.

[0060] The assembly of the modular structures provides a support structure or mounting frame for mounting various functional components of the inventory handling station described above, such as the conveyor system, the container lifting devices, drive motors for the conveyor system and the container lifting devices, electronic and electrical components for operating the drive motors, and / or load cells. In addition to the functional components being mounted to the support structure or mounting frame, the exterior of the support structure may be covered by one or more panels 170 to house the functional components within the housing. The panels 170 may be secured to the horizontal and / or vertical support elements of the assembly of the modular structures by one or more fasteners, such as bolts. Alternatively, the panels 170 may include locking tabs 172 configured to interlock with one or more openings (not shown) of the horizontal and / or vertical support elements 112a, 112b, 114 of the assembly of the modular structures 110 (see FIG. 22). Access is provided via openings 88 in the housing for picking and / or decanting one or more items into a storage container passing over the conveyor units 80, 82.

[0061] By controlling the orientation of the support elements in substantially perpendicular directions, the connector 116 of the present invention has multiple applications in storage and retrieval systems where alignment between adjacent structures is required. For example, in the case of a grid frame structure, the grid openings in the grid structure are aligned with the grid columns formed by a plurality of upright columns to guide the storage containers through the grid openings. The connector of the present invention can be used to control the orientation of the grid members and / or tracks in a grid framework structure, whereby the grid members are arranged in a grid pattern having a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second orientation being substantially perpendicular to the first orientation. For example, instead of the connector 116 functioning as a corner piece with two connecting portions extending in two perpendicular directions in a horizontal plane, the connector has four connecting portions that are perpendicular to each other and in a horizontal plane, whereby the connector is cross-shaped to connect to each grid member in the grid pattern. The contours of the connector keys (e.g., raised bosses) as well as the connecting portions of the corner pieces control the orientation of the grid members as they are arranged in a grid pattern. Track elements may be attached to the grid members to guide movement of one or more robotic load handling devices in first and second directions on the grid structure. It is also possible that multiple modular structures 110 may be arranged at different heights in a grid pattern to form a grid framework structure.

Claims

1. 1. A connector for connecting to at least three support elements of a three dimensional modular structure, said connector comprising: i) a first connector portion for connecting a support element extending in a first direction; ii) a second connector portion for connecting a support element extending in a second direction; and iii) a third connector portion for connecting a support element extending in a third direction, wherein the first, second and third directions are substantially perpendicular to each other; iv) one or more mounting projections, wherein each of said one or more mounting projections has a substantially flat mating surface for mating with a corresponding mounting projection of an adjacent connector; a single body comprising: A connector, wherein each of the first, second and third connecting portions includes a contoured key for controlling the orientation of the support element in their respective first, second and third directions.

2. 2. The connector of claim 1, wherein the profile of the key includes at least two opposing linear edges to prevent rotation of the support element about an axis extending through the key, each of the at least two opposing linear edges defining a load-bearing surface.

3. The connector of claim 2 , wherein the contour of the key is substantially quadrilateral.

4. A connector as claimed in any one of claims 1 to 3, wherein the keys of the first and second connector parts lie in the same plane and are oriented such that lines extending along midpoints of the keys of the first and second connector parts intersect at substantially 90°.

5. 5. The connector of claim 4, wherein the keys of the third connector part lie in a plane perpendicular to the plane of the keys of the first and second connector parts such that the connector has a line of symmetry extending through the keys of the third connector part.

6. A connector as claimed in any preceding claim, wherein the key comprises a raised boss.

7. The connector of claim 6 , wherein the raised boss comprises a substantially flat mating surface.

8. The connector of claim 7 , wherein the raised boss comprises a hole.

9. 9. A connector as claimed in any one of claims 1 to 8, wherein each of the one or more mounting projections comprises a first mounting projection lying in a first mounting projection plane and a second mounting projection lying in a second mounting projection plane, the second mounting projection plane being substantially perpendicular to the first mounting projection plane such that a line extending through the first mounting projection is substantially perpendicular to a line extending through the second mounting projection.

10. 10. A connector as described in any one of claims 1 to 9, wherein each of the one or more mounting projections comprises a first hole and a second hole, the first hole being a threaded hole and the second hole being a non-threaded hole.

11. The connector of any one of claims 1 to 10, further comprising a spacer for spacing adjacent connectors apart.

12. 12. A modular structure comprising a plurality of vertically spaced modular sections, each of the plurality of modular sections comprising at least four connectors according to any one of claims 9 to 11, wherein each of the at least four connectors in a single modular section is connected to two other connectors by horizontal support elements to form a substantially rectangular frame, and each of the at least four connectors of vertically adjacent modular sections are connected together by substantially vertical support elements to form a frame structure, and a distal end of each of the horizontal and vertical support elements comprises an opening having a contour complementary to the contour of the key of the connector, such that an orientation of the horizontal and vertical support elements is controlled by the contour of the key.

13. The modular structure of claim 12 , wherein the connection between the vertical support element and the horizontal support element comprises a bracket.

14. 14. The modular structure of claim 12 or 13, wherein the modular structure has a substantially cubic structure.

15. 15. An assembly comprising a plurality of modular structures according to any one of claims 12 to 14, wherein adjacent modular structures in the assembly are joined together by one or more of their mounting projections.

16. The assembly of claim 15 , wherein the plurality of modular structures are arranged in a stack.

17. 17. The assembly of claim 15 or 16, wherein the plurality of modular structures are arranged side-by-side.

18. 1. An inventory handling station for cooperating with a storage and retrieval system, the storage and retrieval system comprising a grid framework structure, the grid framework structure comprising: a plurality of upright columns arranged in one or more vertical planes to form a plurality of grid columns for stacking one or more containers between and vertically guided by the upright columns, the upright columns being interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members extending transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; the first and second sets of grid members respectively support first and second sets of tracks at an upper level of the grid framework structure for a load handling device to move one or more storage containers on the grid framework structure; An inventory handling station, the inventory handling station assembly comprising an assembly of modular structures according to any one of claims 15 to 17 arranged to support a transport system comprising a plurality of transport units, each of the plurality of transport units being attached to a respective modular section of an adjacent modular structure so as to form a continuous conveyor.

19. The modular assembly comprises: i) a port station for receiving storage containers to be dropped off and picked up through the grid cells; ii) an access station that allows access to one or more storage containers dropped off from said port station; is arranged to support the transport system is arranged to transport storage containers between the port station and the access station.

20. The inventory handling station of claim 18.

20. 20. The inventory handling station of claim 19, wherein the port station comprises a vertical chute configurable to cooperate with at least one upright column, the at least one vertical chute having a first opening for receiving a container lowered by at least one load handling device through a grid cell and a second opening for allowing the container to exit the port station.

21. 21. The inventory handling station of claim 20, wherein the modular assemblies are arranged in a stack to define the vertical chute.

22. 22. The inventory handling station of claim 21, wherein the vertical chute comprises a container lifting device that is configurable, in use, to lift the storage container upwardly towards the grid so that the storage container may be removed by the at least one load handling device.

23. 23. An inventory handling station as claimed in any one of claims 18 to 22, wherein the port station comprises a supply zone for receiving storage containers dropped off through grid cells, and a pick-up zone for picking up storage containers through grid cells.

24. 24. The inventory handling station of claim 23, wherein the plurality of conveyor units comprises an entrance conveyor unit configured in the supply zone, an access conveyor unit disposed in the access station, and an exit conveyor unit disposed in the pickup zone.

25. 25. The inventory handling station of claim 24, wherein the entrance conveyor unit, the exit conveyor unit and the access conveyor unit are arranged to transport storage containers in first, second and third transport directions, respectively, the first transport direction of the entrance conveyor unit being opposite and parallel to the second transport direction of the exit conveyor unit, and the third transport direction of the access conveyor unit being perpendicular to both the first transport direction of the entrance conveyor unit and the second transport direction of the exit conveyor unit.

26. 25. The inventory handling station of claim 24, wherein the entrance conveyor unit, the exit conveyor unit and the access conveyor unit are arranged to transport storage containers in first, second and third transport directions, respectively, and the conveyor system is arranged such that the first transport direction of the entrance conveyor unit is perpendicular to both the second transport direction of the exit conveyor unit and the third transport direction of the at least one access conveyor unit.

27. An inventory handling station according to any one of claims 18 to 26, wherein the port station and / or the access station comprise load cells.

28. 1. A fulfillment / decanting system comprising: i) a storage and retrieval system comprising a grid framework structure, said grid framework structure comprising: a plurality of upright columns arranged in one or more vertical planes to form a plurality of grid columns for stacking one or more containers between and vertically guided by the upright columns, the upright columns being interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members extending transversely to the first set of grid members in a substantially horizontal plane to form a grid or grid structure comprising a plurality of grid cells or grid spaces; a storage and retrieval system, the first and second sets of grid members supporting a first set of tracks and a second set of tracks, respectively, at an upper level of the grid framework structure for a robotic load handling device to move one or more storage containers on the grid framework structure; ii) one or more load handling devices remotely operated to move the one or more containers stored on the grid framework structure, each of the one or more load handling devices comprising: i) a wheel assembly for guiding said load handling apparatus on said grid structure; ii) a container receiving space located above the grid structure; and iii) a lifting device arranged to lift a single container from the stack into said container receiving space; iii) an inventory handling station according to any one of claims 18 to 27, wherein said inventory handling station is configured to receive one or more storage containers from said storage and retrieval system; A fulfillment / decant system comprising:

Images