A warehouse system for storing and retrieving goods in containers

Abstract

A product order fulfillment system for mixed product units is provided, the product order fulfillment system comprising a storage array and an automated transport system, the storage array having at least one elevated storage level, the mixed product units being input to and distributed in cases of a common type of product units per case into the storage array, the automated transport system having at least one asynchronous transport system for level transport and a lift for inter-level transport, communicatively connected to the storage array for automatically retrieving and outputting the distributed product units in cases in at least one elevated storage level of the storage array, the output product units being one or more mixed and singulated product units in mixed pack groups and mixed cases, and the at least one asynchronous transport system and lift configured to form two or more transport channels.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a nonprovisional application and claims the benefit of U.S. Provisional Application No. 63 / 365,368, filed May 26, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] The disclosed embodiments relate generally to material handling systems, and more specifically, to the transport and storage of items within material handling systems. [Background technology]

[0003] A brief description of related developments It is well recognized that the integration of automated storage and retrieval systems into a logistics chain, particularly a goods to man system, is highly beneficial in terms of efficiency and cost throughout the logistics chain. Conventional systems, even with the integration of highly automated storage and retrieval systems within a logistics facility, generally operate by storing product (e.g., supply) containers, where the supply containers house cases, packs, etc., containing a common type of commodity (also called product). The product containers may arrive on pallets (e.g., common supply containers) or as truck loads, are depalletized or unloaded from the truck, stored at the logistics facility, and distributed by the automated storage and retrieval system throughout the logistics facility's storage volume (e.g., in a three-dimensional array of storage racks).

[0004] Advances in electronic commerce and just-in-time inventory systems allow customers of a logistics facility to purchase small quantities of a particular item, rather than full cases of a particular item, resulting in the generation of mixed product containers. Generally, order fulfillment from a logistics facility, particularly when mixed product containers are desired (e.g., where any given order container may have mixed / different products or product types held by a common container, such as in cases of direct to consumer fulfillment, or in cases of indirect fulfillment to a consumer via a retail order pick-up location, etc., where the mix of ordered products in the order container is generated, at least in part, at the logistics facility prior to shipment from the logistics facility), traditionally, the generation of mixed product containers is accomplished by the goods to person (GTP) of an automated storage and retrieval system. Using a (person) configuration, the automated storage and retrieval system is enabled by outputting product / supply containers (each of which contains one or more merchandise items of a common merchandise type, i.e., each merchandise item in a product container is the same or substantially similar) from storage locations throughout the three-dimensional array of storage racks to workstations, manually or automatically picking and removing goods from the various product / supply containers supplied to a given workstation by the automated storage and retrieval system in accordance with a given fulfillment (or fill) order, and placing the various picked goods (which may be combined or contained in common if the given order is so filled) into the order container.Such workstations may be called breakpack stations, where a product container is "disassembled" and its contents may be placed in whole or in part into an order container or what is called a breakpack storage container (e.g., a tote bag), for example, where the product container is not suitable for continuing to hold the remaining product articles after the breakpack operation, and such remaining product (i.e., the remainder of the product in the "disassembled" product container) should be returned to a storage location in the three-dimensional array of storage racks by the automated storage and retrieval system. To increase efficiency, the order container may be placed in a storage location on the three-dimensional array of storage racks, possibly storing the product container, and then both input and output from the three-dimensional array of storage racks are otherwise enabled by the automated storage and retrieval system, such as when order output is desired. Improved systems for processing disassembled products into at least mixed product cases are desired. Summary of the Invention

[0005] The foregoing aspects and other features of the disclosed embodiments are explained in the following description, taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0006] [Figure 1A] 1 is a schematic diagram of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1B] FIG. 1B is a schematic diagram of a portion of the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 1C] FIG. 1B is a schematic diagram of a mixed pallet load formed by the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Diagram 2] FIG. 1B is a schematic diagram of a portion of the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 3A]FIG. 1B is a schematic diagram of a portion of the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 3B] 1B is a schematic diagram of a portion of the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 4A] FIG. 1B is an exemplary flow diagram for product group set formation in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 4B] FIG. 1B is an exemplary flow diagram for product group set formation in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 4C] FIG. 1B is an exemplary flow diagram for product group set formation in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 5A] FIG. 4B is a schematic diagram of the method of FIGS. 4A-4C according to aspects of the disclosed embodiment. [Figure 5B] FIG. 4B is a schematic diagram of the method of FIGS. 4A-4C according to aspects of the disclosed embodiment. [Figure 5C] FIG. 4B is a schematic diagram of the method of FIGS. 4A-4C according to aspects of the disclosed embodiment. [Figure 5D] FIG. 4B is a schematic diagram of the method of FIGS. 4A-4C according to aspects of the disclosed embodiment. [Figure 5E] FIG. 4B is a schematic diagram of the method of FIGS. 4A-4C according to aspects of the disclosed embodiment. [Figure 5F] FIG. 4B is a schematic diagram of the method of FIGS. 4A-4C according to aspects of the disclosed embodiment. [Figure 6] FIG. 13 is an exemplary diagram of allocation of products to commercial categories and commercial divisions in accordance with aspects of the disclosed embodiment; [Figure 7] FIG. 1 is an exemplary schematic diagram of a commercial palletized package delivery according to an aspect of the present disclosure. [Figure 8] FIG. 1 is an exemplary schematic diagram of a commercial palletized package delivery according to an aspect of the present disclosure. [Figure 9] FIG. 1 is an exemplary schematic diagram of a commercial palletized package delivery according to an aspect of the present disclosure. [Figure 10] FIG. 1B is a schematic diagram of a containerization flow through the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 11A] FIG. 1B illustrates an exemplary flow diagram for product containerization in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 11B] FIG. 1B illustrates an exemplary flow diagram for product containerization in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 11C] FIG. 1B illustrates an exemplary flow diagram for product containerization in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 11D] FIG. 1B illustrates an exemplary flow diagram for product containerization in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 12] FIG. 11C is a schematic diagram of containerization according to the method of FIGS. 11A-11D in accordance with aspects of the disclosed embodiment. [Figure 13] FIG. 1B is a schematic diagram of product sequencing in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 14A] FIG. 1B is a schematic diagram of sequencing / order flow in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 14B] FIG. 1B is a schematic diagram of sequencing / order flow in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment; [Figure 15A] FIG. 1B is an exemplary flow diagram for ordering products in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 15B] FIG. 1B is an exemplary flow diagram for ordering products in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 15C]FIG. 1B is an exemplary flow diagram for ordering products in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 15D] FIG. 1B is an exemplary flow diagram for ordering products in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 15E] FIG. 1B is an exemplary flow diagram for ordering products in the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 16] FIG. 1B is an exemplary flow diagram for a method enabled by the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. [Figure 17] FIG. 1B is an exemplary flow diagram for a method enabled by the automated storage and retrieval system of FIG. 1A in accordance with aspects of the disclosed embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] 1A is a schematic diagram of an automated storage and retrieval system (also referred to herein as a warehouse system or a product order fulfillment system) 100 in accordance with aspects of the disclosed embodiment. The automated storage and retrieval system may be located in a warehouse 199 or any other suitable location. Although aspects of the disclosed embodiment will be described with reference to the drawings, it should be understood that aspects of the disclosed embodiment can be embodied in many forms. Additionally, any suitable size, shape, or type of elements or materials may be used.

[0008] As described herein, aspects of the disclosed embodiments provide a break-pack system with containerization and sequencing optimized for end-user (e.g., customer / consumer) requests or order fulfillment. Aspects of the disclosed embodiments result in grouping of product units BPG (also referred to as vendor packs, eaches, or break-pack goods, each of which has a respective three-dimensional shape) within a bounded area (such as any suitable shipping container) based on one or more of product group characteristics and predefined rules associated with a customer order 299 (see FIG. 2). By way of example, the controller 120 of the storage and retrieval system 100 is programmed with store / customer rules SR (e.g., product characteristic framework (see FIG. 2)) that define product (goods) groups PGA-PGn and their complementarity, similarity, and / or fusion potential with respect to one another.

[0009] According to aspects of the disclosed embodiment, warehouse packs or case units CU holding product units BPG are input into the automated storage and retrieval system 100 (e.g., as described herein) and grouped into product groups PGA, PGB, PGC (see FIG. 2 where three product groups are illustrated for illustrative purposes only, but note that any number of product groups may be present), each product group having unique pre-defined product group characteristics that result in the merging (e.g., biasing) of product units BPG (e.g., for containerization) of one product group PGA, PGB, PGC with product units BPG of the same product group PGA, PGB, PGC or with product units BPG of a different product group PGA, PGB, PGC. These product groups PGA, PGB, PGC are assigned and distributed to respective storage or pick levels 130L (also referred to herein as lift storage levels or lift storage and transport levels) of the storage structure 130 based on at least the fusibility of the product units BPG to enable orthogonal processing of the product groups PGA, PGB, PGC at the respective storage levels 130L (wherein "orthogonal" as used herein means uncorrelated or lacking a relationship or connection with each other, independent). Here, the fusibility of the product units BPG within the product groups PGA, PGB, PGC separates or normalizes the commodity categories (e.g., personal hygiene products, household products, detergents, clothing, small appliances, groceries, etc.) from the customer order 299 (see FIG. 2) to provide orthogonal processing of the product groups PGA, PGB, PGC. It is noted that each of the at least one lifting storage and transport level 130L is separate and distinct (or may be separate and distinct) from each other lifting storage and transport level 130L, where each lifting storage and transport level 130L provides an orthogonal transport output of product units distributed to the storage array 130SA relative to each other lifting storage and transport level 130L.As described herein, product groups PGA, PGB, PGC may be dynamically reallocated between product levels (e.g., based on the blending potential (as described herein) of different product groups). For example, if there is an excess or abundance of a product at one transport level (e.g., transport level 130L1), some of the warehouse packs CUA, CUB, CUC, Cui holding the product may be dynamically reallocated to another transport level 130 (e.g., one or more of transport levels 130L2, 130L3), where product group PGA (or at least one of its warehouse packs CU) is blendable with one or more of product groups PGB, PGC of the other storage levels 130L2, 130L3. Reallocation of product groups between transport levels may maintain approximately equal work divisions (e.g., transport transaction rates) between transport levels.

[0010] The product units BPG of the warehouse pack CU from the product groups PGA, PGB, PGC are virtually containerized by the controller 120 of the automated storage and retrieval system 100 to enable a filling plan for a given shipping container (referred to herein as a container). The product units BPG are batched together in the container, for example, based on application of the blendability of the product units BPG with each other. Once the filling plan is established, the product units BPG from the product groups PGA, PGB, PGC are picked from the respective storage level(s) 130L of the storage array 130SA (e.g., of the storage structure 130) and transported to the break-pack station 140 to result in the filling of the given container(s). The product units BPG are sequenced in any suitable manner (e.g., during the transport of the product units from the storage level 130L to the break-pack station 140 and / or from the break-pack station 140 to the container) to fill the container.

[0011] Grouping warehouse packs CU based at least on the blendability of product units BPG held in the warehouse packs CU may appear to increase the number of trips of the autonomous guided vehicles 110 from the storage spaces 130S in the storage array 130SA to, for example, the break-pack station 140 to fill containers (e.g., aspects of the disclosed embodiment increase the number of commodity categories at each level where each vehicle 110 transports one case unit CU corresponding to each commodity category per trip), but counterintuitively, placing warehouse packs CUs in storage levels 130L based on the blendability of product units BPG optimizes the transfer of case units (e.g., reduces the number of trips) because product units BPG of one warehouse pack CU may be utilized to fill two or more containers in any given transport of that warehouse pack CU. Note that the blendability of product units BPG is a measure of the batching of product units BPG into any given container, resulting in the batching of product units BPG into any given container.

[0012] Orthogonal processing of the warehouse packs CU of product groups PGA, PGB, PGC, where the warehouse packs CU are grouped based at least on the fusion potential of the product units BPG held in the warehouse packs CU, allows the fusion-capable product units BPG to be linked together, where it is known that for a given warehouse pack transport, there are product units suitable for batch processing. For example, also referring to FIG. 2, the product group PGA may include warehouse packs (or case units) CUA, CUB, CUC, CUi, each containing a product unit A, B, C, i. A customer order may be placed for the product units A+i, B+i, C+i. Here, the vehicle 110 at the storage level 130L corresponding to the product group PGA transports the warehouse packs CUA, CUB, CUC, CUi, each holding a product unit A, B, C, i, to the break-pack station 140. Because product units A, B, C, i are known to be blendable with one another based on the product group PGA to which the warehouse pack is assigned, product unit i can be batched with each of product units A, B, C, where the three customer orders are fulfilled with only one transport trip of warehouse pack CUi from storage array 130SA to break pack station 140. In effect, the known blendability of product units BPG within a given product group increases the probability (or "hit rate") that any given warehouse pack CU of that given product group will be utilized for two or more container fills in any given single transport trip.

[0013] Still referring to FIG. 1 , according to aspects of the disclosed embodiment, an automated storage and retrieval system 100 may operate at a retail distribution center or warehouse to fulfill orders received from various customers (such as those described herein) for, for example, break-packed goods BPG and / or warehouse packs (also referred to herein as case units) CU. Suitable examples of automated storage and retrieval systems that incorporate or can incorporate a break-packed goods system are described, for example, in U.S. Patent No. 10,822,168, issued November 3, 2020, U.S. Provisional Patent Application No. 17 / 657,705, filed April 1, 2022 and entitled “Warehousing System for Storing and Retrieving Goods in Containers,” and U.S. Provisional Patent Application No. 17 / 358,383, filed June 25, 2021 and entitled “Warehousing System for Storing and Retrieving Goods in Containers,” the disclosures of which are incorporated herein by reference in their entirety.

[0014] As an example, a warehouse pack CU is a case or unit of goods that is not stored (e.g., not contained) in a tray, on a tote, or on a pallet. In another example, a warehouse pack CU is a case or unit of goods that is packaged in any suitable manner, such as in a tray, on a tote, in a container (such as a container of remaining goods after a break pack where the broken down warehouse pack structure is not suitable for transport of the remaining goods as a unit), on a pallet, etc. In yet another example, a warehouse pack CU is a combination of unpackaged and packaged goods. It is noted that a warehouse pack CU includes, for example, cased units of goods (e.g., a case of multiple soup cans, multiple boxes of cereal, etc.) or individual goods that are adapted to be removed from or placed on a pallet. According to aspects of the disclosed embodiment, a transport case (e.g., a carton, barrel, box, crate, jug, or any other suitable device for holding a case unit) for a warehouse pack CU may have a variable size, may be used to hold the case unit during transport, and may be configured to be palletized for transport.

[0015] It is noted that, for example, when multiple bundles of warehouse packs CU or multiple pallets (e.g., mixed product units) arrive at the storage and retrieval system 100 (see "Goods Input" in FIG. 2), the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same items, i.e., one pallet holds soup and another pallet holds cereal), and when the pallets leave the storage and retrieval system, they may contain any suitable number and combination of different warehouse packs or containerized product units BPG (e.g., a mixed pallet where each mixed pallet holds different types of warehouse packs and / or containerized product units BPG, i.e., a pallet holds a combination of soup and cereal), which are provided to a palletizer in a sorted arrangement to form, for example, a mixed pallet (e.g., enabled by at least the pallet output sorting 185 stage of the automated storage and retrieval system 100, where at least one or more of the containerbots 110 and lift modules 150B transport the case units for sorting). In accordance with aspects of the disclosed embodiment, the storage and retrieval system 100 described herein may be applied to any environment in which warehouse packs CU are stored and retrieved.

[0016] 1A and 1B, according to an aspect of the disclosed embodiment, the automated storage and retrieval system 100 includes one or more break-pack modules 266 (see FIG. 1B) configured to break down product containers or warehouse packs CUs (which may be generally referred to as supply goods containers or supply containers 265) into break-pack goods containers 264 (used to ship break-pack goods, e.g., shipping containers) for order fulfillment in a manner similar to that described in U.S. Provisional Patent Application No. 17 / 657,705, filed April 1, 2022, entitled "Warehousing System for Storing and Retrieving Goods in Containers," and U.S. Provisional Patent Application No. 17 / 358,383, filed June 25, 2021, entitled "Warehousing System for Storing and Retrieving Goods in Containers," the entire disclosures of which have been previously incorporated by reference herein. The one or more break pack modules 266 may be communicatively coupled to one or more stacked (storage) levels 130L of the automated storage and retrieval system 100, where the one or more levels 130L of the automated storage and retrieval system 100 include at least one break pack module 266. The break pack module(s) 266 may be a plug-and-play module that may be coupled to any appropriate portion of the structure of the automated storage and retrieval system 100. For example, the break pack module(s) may be coupled to the container transfer deck 130DC (see also container transfer deck 130DC2 in FIG. 1B) or the picking (or pick) aisle(s) 130A of the automated storage and retrieval system 100. The break pack module(s) 266 may be disposed in any appropriate number of stacked storage levels of the automated storage and retrieval system 100.

[0017] Any suitable controller 120 may be configured to enable operation of the automated storage and retrieval system 100 described herein. For example, the controller 120 may be configured to build an order for break-pack goods or product units BPG from a supply container or case unit (also referred to herein as a warehouse pack) to a break-pack goods container 264 (see FIG. 1A ) and enable operation of at least one container bot or autonomously guided autonomous vehicle 110 and at least one goods bot or autonomously guided break-pack goods transport vehicle 262, as well as any lifts 310A, 310B, and other components of the automated storage and retrieval system 100 described herein, for removal of the break-pack goods container 264 to an output station 160UT via a container removal station TS. For example, the controller 120 is configured to enable operation of the container bot(s) 110 between the container storage location 130S, the break-pack operation station 140, and a break-pack commodity container 264 located at a put wall 263W along the break-pack commodity transfer deck or commodity deck 130DG (e.g., a break-pack commodity container 264 located at the break-pack commodity interface station / container station 263L of the put wall 263W). As another example, the controller 120 is configured to enable operation of the goods bot(s) 262 to sort (e.g., at the break-pack order sorting 188 stage of the automated storage and retrieval system 100 as described herein) the break-pack commodity BPG into a corresponding break-pack commodity container 264 upon transport of the break-pack commodity BPG by the goods bot 262 traveling on the commodity transfer deck 130DG.As a further example, the controller 120 is configured to enable operation of the container bot(s) 110 to access corresponding break-pack commodity containers 264 from the put wall 263W at the commodity transfer deck 130DG and transport the break-pack commodity containers 264 via passage along the container transfer deck 130DC to the container output / transfer station TS and at least one of the corresponding container storage positions 130SB of the storage shelves of the corresponding level 130L of the multi-level storage array (e.g., to at least partially enable the break-pack output classification 189 stage as described herein).

[0018] The controller 120 also includes a controller 122 that is connected to the controller 122. The controller 120 also includes a controller 122 that is connected to the controller 122. The break-pack commodity container 264 is configured to enable operation of the container bot(s) 110 and the lift 150 (e.g., to form a container supply system) to introduce the empty break-pack commodity container 264 into the automated storage and retrieval system and into the break-pack module for placement at the break-pack commodity interface(s) 263L of the break-pack commodity interface(s) 263 for transfer of the break-pack commodity BPG to the break-pack commodity container 264, such that the container bot(s) 110 transport the empty break-pack commodity container 264 along the transport / movement loop 233BP of the container transfer deck(s) 130DC in a manner similar to that described in U.S. Provisional Patent Application No. 63 / 044,721, filed June 26, 2020, and U.S. Non-Provisional Patent Application No. 17 / 358,383, filed June 25, 2021, both of which are incorporated herein by reference. It is noted that the break-pack commodity interface 263 may be generally similar to one or more of the transfer stations TS and buffer stations BS described herein and may include a non-deterministic surface (similar to the non-deterministic surface of the rack storage space 130S described herein) (e.g., or otherwise, a container bot moving surface(s) 266RS forming part of or communicatively coupled to the container transfer deck) on which the break-pack commodity container 264 is placed to form a non-deterministic interface between the commodity transfer deck 130DG and the container transfer deck 130DC.In other embodiments, the empty break pack product container 264 may be transferred to a storage space 130SB, 130S (FIG. 1B) of the rack module RM (in a manner similar to that described above with respect to the lift and container bots) and stored there, or temporarily stored at an in-feed station, where the controller 120 is configured to enable transfer of the empty break pack product container 264 from the storage space 130SB, 130S or a buffer position to the break pack product interface 263 in a manner similar to that described above.

[0019] In one or more embodiments, the controller 120 is configured to enable operation of the container bot(s) 110 and the lift 150 (e.g., to form a container supply system) to introduce an empty supply container 265 or a standardized container 265S (as described herein) into the automated storage and retrieval system (in a manner similar to that described in U.S. Provisional Patent Application No. 63 / 044,721, filed June 26, 2020, and U.S. Non-Provisional Patent Application No. 17 / 358,383, filed June 25, 2021, both of which are entitled "Warehousing System for Storing and Retrieving Goods In Containers", the disclosures of which have both been previously incorporated by reference in their entireties) so that the container bot(s) 110 transport the empty supply container 265 or the standardized container 265S along the transport / movement loops 233, 233A of the container transfer deck(s) 130DC to the break pack operation station 140 of the break pack.

[0020] As can be appreciated, the container bots 110, goods bots 262, lift modules 150, break pack modules 266, and other suitable features of the storage and retrieval system 100 are controlled in any suitable manner, such as by one or more central system control computers (e.g., control server) 120, via any suitable network 180, to effect the operations described herein. In one aspect, the network 180 is a wired network, a wireless network, or a combination of wireless and wired networks using any suitable type and / or number of communication protocols. In one aspect, the control server 120 includes a collection of substantially simultaneously executing programs (e.g., non-transitory computer program code / system management software) for substantially automatic control of the automated storage and retrieval system 100, as described herein. The collection of substantially concurrently executing programs is configured to manage the storage and retrieval system 100, including, for example, by way of example only, controlling, scheduling, and monitoring the activity of all active system components, managing inventory (e.g., which case units are entered and removed, the order in which the cases are removed, and where the case units are stored) and pick faces (e.g., one or more case units that are movable as a unit and are handled as a unit by the components of the storage and retrieval system), and interfacing with warehouse management system 2500. Control server 120, in one aspect, may be configured to control the features of the storage and retrieval system in the manner described herein.

[0021] 1C, it is noted that, for example, when incoming bundles or pallets (e.g., from a case unit manufacturer or supplier) arrive at the storage and retrieval system for replenishment of the automated storage and retrieval system 100 (again, see, e.g., item input in FIG. 2), the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same items, i.e., one pallet holds soup, another pallet holds cereal). As can be appreciated, the warehouse packs or case units CU of such a pallet load may be substantially similar, or in other words, homogenous cases (e.g., similar dimensions) and may have the same SKU (otherwise, as previously discussed, the pallets may be "rainbow" pallets having layers formed of homogenous cases). As the pallet PAL exits the storage and retrieval system 100, with the cases filled with customer replenishment orders, the pallet PAL may contain any suitable number and combination of various case units CU (collectively, i.e., unreleased, supply containers 265) and / or break-pack commodity containers 264 (collectively referred to as "shipping containers" or "cases," where, for example, each pallet may hold different types of shipping containers with different types of commodity categories, i.e., a pallet may hold a combination of canned soup, cereal, drink packs, cosmetics, and household cleaners). The cases combined on a single pallet may be of different dimensions and / or different SKUs.

[0022] In one aspect of the disclosed embodiment, the storage and retrieval system 100 may be generally configured to include an in-feed section, a storage and sorting section (where, in one aspect, storage of the items is optional and sorting is done in one or more of various orthogonal sorting as described herein), and an output section (which may also provide sorting, e.g., in one or more of various orthogonal sorting as described herein), as described in more detail below. As can be appreciated, in one aspect of the disclosed embodiment, the system 100 operating, for example, as a retail distribution center, may be responsible for receiving homogenous pallet loads of cases, breaking down the palletized goods or separating the cases from the homogenous pallet loads into separate case units that are individually processed by the system, removing and sorting the various cases required by each order into corresponding groups, and transporting and assembling the corresponding groups of cases into what is referred to as a mixed case pallet load MPL. As may also be appreciated, in one aspect of the disclosed embodiments, the system 100 operating as, for example, a retail distribution center may be responsible for receiving uniform pallet loads of cases, breaking down the palletized goods or separating the cases from the uniform pallet loads into separate case units that are processed separately by the system, removing and sorting the various cases required by each order into corresponding groups, and transporting and ordering the corresponding groups of cases in the manner described in U.S. Pat. No. 9,856,083, issued Jan. 2, 2018, having U.S. patent application Ser. No. 14 / 997,920, the entire disclosure of which is incorporated herein by reference.

[0023] The automated storage and retrieval system 100 is configured to assemble appropriate groups of ordered cases, which may vary in SKU, size, etc., into mixed case pallet loads (including one or more of the case units and / or break pack containers 264) and / or break pack containers 264, as described in U.S. Provisional Patent Application No. 63 / 044,721, filed June 26, 2020, and U.S. Nonprovisional Patent Application No. 17 / 358,383, filed June 25, 2021, both of which are entitled “Warehousing System for Storing and Retrieving Goods In Containers,” the disclosures of which are both previously incorporated by reference in their entireties. For example, when mixed case pallet loads are assembled, the output section of the automated storage and retrieval system 100 generates the pallet load in what may be referred to as a structured architecture of a mixed case stack. The structured architecture of the pallet load described herein is representative, and in other aspects, the pallet load may have any other suitable configuration. For example, the structured architecture may be any suitable predefined configuration, such as a load container envelope for holding truck bay loads or other suitable containers or structural loads. The structured architecture of a palletized load may be characterized as having several flat case layers L121-L125, L12T, as described in U.S. Pat. No. 9,856,083, previously incorporated by reference in its entirety. As a further example, break pack containers 264 may be assembled and output by an output section of the automated storage and retrieval system 100 for individual shipment to a customer or shipment in other break pack containers 264 to one or more customers.

[0024] 3A and 3B, to assemble one or more of the mixed pallet loads, individual break-pack containers 264, and grouped break-pack containers 264, the controller 120 may operate the container bots 110, the goods bots 262, the lift modules 150, the break-pack modules 266, and other suitable features of the storage and retrieval system 100 such that various orthogonal sorting steps occur. For example, the case bot 110 may perform a pallet out sorting 185 step, which removes case units from storage and outputs them for inclusion in the mixed pallet load. The case bots 110 and one or more of the break-pack module lifts 310A, 310B may also perform a break-pack station input sorting 186 step (orthogonal to / independent of the pallet output sorting 185), which provides supply containers 265 to the break-pack module 266 in a predetermined order. Each break-pack operation station 140 of the break-pack module 266 may also perform an orthogonal sorting (e.g., break-pack station output sorting 187 step) of break-pack goods BPG to a goods bot 262, which is configured to perform another orthogonal sorting (e.g., break-pack order sorting 188 step) of break-pack goods RGB to a break-pack container 264 at a put wall 263W. The casebot 110 picks the break-pack container 264 from the put wall 263W and provides a break-pack output sorting 189 step (orthogonal to steps 185-188) to an output section of the automated storage and retrieval system 100.

[0025] According to aspects of the disclosed embodiment, and referring again to FIG. 1A, the automated storage and retrieval system 100 includes an input station 160IN (including a depalletizer 160PA and / or a conveyor 160CA for transporting items (e.g., inbound supply containers) to lift the module 150A for entry into a storage level 130L of a storage structure or multi-level container storage array 130SA), and output stations 160UT, 160EC (including a palletizer 160PB, an operator station 160EP and / or a conveyor 160CB) for transporting items (e.g., outbound supply containers and filled break-pack goods (order) containers) from the lift module 150B for removal from the storage (e.g., to a palletizer (for palletizer loads) or to a truck (for truck loads)). Here, output station 160EC is an individual fulfillment (or e-commerce) output station where, for example, filled break-pack merchandise (order) containers containing single items of merchandise and / or small bundles of merchandise are transported to fulfill individual fulfillment orders (such as orders placed by consumers on the Internet). Output station 160UT is generally a commercial output station where a number of items are provided on pallets to fulfill orders from commercial entities (e.g., commercial stores, warehouse clubs, restaurants, distribution centers (e.g., where items such as break-pack merchandise, case units, pick faces, etc. are held for shipment to individual customers), etc.). As can be appreciated, while automated storage and retrieval system 100 includes both commercial output station 160UT and individual fulfillment output station 160EC, other embodiments include one or more of commercial output station 160UT and individual fulfillment output station 160EC.

[0026] The automated storage and retrieval system 100 also includes input and output vertical lift modules 150A, 150B (generally referred to as lift modules 150, and although an input lift module and an output lift module are shown, it is noted that a single lift module may be used to load and unload case units from the storage structure), a storage structure 130 (which may have at least one lifted storage level (also referred to herein as a lifted storage and transport level) and in some embodiments forms a multi-level storage array 130SA), and at least one autonomous guided container transport vehicle or containerbot 110 that may be constrained to each storage level of the storage structure 130 and that are separate from the transfer deck 130DC (also referred to herein as a transport area) on which they travel (or within). It is noted that the depalletizer 160PA may be configured to remove case units from the pallet so that the input station 160IN can transport the items to the lift module 150 for loading into the storage structure 130. The palletizer 160PB may be configured to place articles retrieved from the storage structure 130 onto a pallet PAL (FIG. 1C) for transport. As used herein, the lift module 150, storage structure 130, break-pack module 266, goods bot 262, and container bot 110 may be collectively referred to herein as a multi-level automated storage system (storage and sorting section) as described above to define (e.g., relative to the reference frame of the container bot 110 or any other suitable storage and retrieval system) transport / throughput axes (e.g., in three dimensions) useful for a three-dimensional multi-level automated storage system, where each throughput axis has essential "on the fly sortation" (e.g., sorting of case units while the case units are being transported) such that sorting and throughput of case units occurs substantially simultaneously without a dedicated sorter as described in U.S. Pat. No. 9,856,083, previously incorporated by reference in its entirety.

[0027] As an example of case unit or break-pack goods container throughput related to sorting, also referring to FIG. 3B, the storage and retrieval system 100 includes several areas or regions of throughput. For example, there is a multi-level case unit storage throughput 130LTP that enables the placement of case units in the storage. The placement / organization of case units in the storage space 130S can be separated / independent from the sorting of case units and / or break-pack goods BPG in the various sorting stages described herein (e.g., not pre-staged therefor). The horizontal case unit transport throughput 110TP results in the transfer of case unit(s) from the storage along the picking aisle, the transfer deck, and to / from the break-pack goods interface. The horizontal case unit transport throughput 110TP at least partially performs one or more of the pallet output sorting 185 stage and the break-pack station input sorting 186 stage. The pallet output sorting 185 sorts case units for mixed pallet loads, but such case units are not provided to the break-pack station 266. Break-pack station throughput 266TP (e.g., break-down of supply cases at a break-pack operation station) results in one or more of a break-pack station input sortation 186 stage (e.g., via break-pack module lifts 310A, 310B) and a break-pack station output sortation 187 stage (via break-pack operation station 140). Horizontal goods transport throughput 262TP provides transfer of break-pack goods from the break-pack operation station 140 to the break-pack goods interface, resulting in a break-pack order sortation 188 stage. Case buffer throughput BTSTP provides temporary storage of case units to facilitate transfer of case units between storage / break-pack and vertical transport, and may result, at least in part, in one or more of a pallet output sortation 185 and a break-pack output sortation 189.The vertical transport throughput 150TP enables the transfer of case units by the vertical lift 150 and may further facilitate, at least in part, one or more of the pallet output sorting 185 and the break-pack output sorting 189. A throughput at the output station 160TP is also provided, which may include, for example, transport by the conveyor 160CB and palletization by the palletizer 160PB. In one aspect, case unit sorting is enabled (e.g., "on the fly") generally in line with the case unit throughputs 130LTP, 110TP, 266TP, 262TP, BTSTP, 150TP along each throughput axis (e.g., X, Y, Z axes relative to the reference frame of the containerbot 110 and / or lift 150), as described herein, with sorting along each axis being independently selectable to be enabled along one or more of the X, Y, Z axes.

[0028] 1A and 1B, the storage structure 130 may include container autonomous transport movement loop(s) 233, 233A disposed at each level of the storage structure 130 (e.g., formed on and along the container transfer deck 130DC). It is noted that the lifts 150 are connected to the container transfer deck 130DC via transfer stations TS (also referred to herein as container loading stations when the lift 150 is an inbound lift 150A or container unloading stations when the lift 150 is an outbound lift 150B), each configured to lift one or both of the supply containers 265 (empty or filled) and the break-pack commodity containers 264 (empty or filled, where a filled break-pack commodity container 264 is one that is ready for shipment and is filled such that the break-pack commodity BPG in the container occupies at least about 30% or at least about 50% of the total container volume) to and from at least one lift storage level 130L of the storage structure 130. An array of storage shelves 130SA (e.g., forming at least a portion of the storage area of ​​storage structure 130, also referred to herein as a multi-level container storage array) is comprised of container storage locations (or spaces) 130S circumferentially arranged along a container transfer deck 130DC, where the transport area of ​​storage structure 130 is substantially continuous and includes at least the transfer deck 130DC and the picking aisle 130A, whereby the transfer area communicatively connects each storage shelf of the array of storage shelves 130SA to one another. A plurality of storage rack modules RM (FIG. 1B), for example arranged in a high-density three-dimensional rack array RMA, are accessible by a storage level or deck level 130L.As used herein, the term "high density three-dimensional rack array" refers to a three-dimensional rack array RMA having non-deterministic open shelves distributed along a picking aisle 130A, where in some embodiments, multiple stacked shelves are accessible from a common picking aisle movement surface or picking aisle level, as described in U.S. Pat. No. 9,856,083, previously incorporated by reference in its entirety.

[0029] Each storage level 130L includes pick face storage / handoff spaces 130S (referred to herein as storage spaces 130S or container storage locations 130S) arranged circumferentially along a container transfer deck 130DC. At least one of the storage locations 130S is a supply container / warehouse pack WHPK storage location 130SS (generally referred to as a case unit CU), and another of the container storage locations is a break pack goods (or order) container storage location 130SB. The storage space 130S is formed, in one embodiment, by rack modules RM, where the rack modules include, for example, shelves arranged along a storage or picking aisle 130A (connected to the container transfer deck 130DC) that extends linearly through the rack module array RMA and provides access for the container bot 110 to the storage space 130S and the transfer deck 130B (e.g., the container bot 110 is configured to traverse the container transfer deck 130DC and the picking aisle 130A at each respective level(s) and transport accessed containers (such as those described herein) between the container storage locations / spaces (such as those described herein) on each of the respective storage shelves at each respective level(s) of the storage structure 130 to the break-pack operation station 140). In one embodiment, the shelves of the rack modules RM are arranged as multi-level shelves distributed along the picking aisle 130A. As can be seen, the container bots 110 move along the picking aisles 130A and container transfer decks 130DC in their respective storage levels 130L to transfer case units between any of the storage spaces 130S of the storage structure 130 (e.g., at the level at which the container bots 110 are located) and any of the lift modules 150 (e.g., each of the container bots 110 has access to each storage space 130S at their respective level and each lift module 150 at their respective storage level 130L).

[0030] The container transfer decks 130DC may be stacked on top of each other or arranged at various levels (corresponding to each level 130L of the storage and retrieval system) that may be horizontally offset, such as having one container transfer deck 130DC at one end or side RMAE1 of the storage rack array RMA or at several ends or sides RMAE1, RMAE2 of the storage rack array RMA, as described in U.S. Patent No. 10,822,168, issued November 3, 2020, the entire disclosure of which is incorporated herein by reference. The container transfer decks 130DC are substantially open and configured for non-deterministic passage of the container bot 110 along multiple movement lanes across and along the transfer deck 130B (e.g., along the X throughput axis relative to the bot's reference frame REF illustrated in FIG. 6D). As described in U.S. Patent No. 10,556,743, issued Feb. 11, 2020, the entire disclosure of which is incorporated herein by reference, the multiple travel lanes may be configured to provide multiple access paths or routes to each storage location 130S (e.g., pick faces, case units, containers, or other items stored in the storage shelves of the rack module RM) so that the containerbot 110 may reach each storage location, for example, using a secondary path if the primary path to the storage location is blocked. As can be seen, the transfer deck(s) 130B at each storage level 130L communicates with each of the picking aisles 130A at the respective storage level 130L.

[0031] As the container bot 110 moves along the picking aisles (e.g., along the X throughput axis relative to the bot's reference frame REF illustrated in FIG. 6D ), it travels bidirectionally between the container transfer deck 130DC (or decks) at each storage level 130L and the picking aisles 130A, accessing storage spaces 130S arranged on rack shelves alongside each of the picking aisles 130A (e.g., the container bot 110 may access storage spaces 130S distributed on both sides of each aisle along the Y throughput axis, such that the container bot 110 may have a different face when traveling through each picking aisle 130A, e.g., the drive wheels 110 of the container bot 110 leading in the direction of movement or drive wheels following in the direction of movement). It will be understood that the container bot 110 may have a different face when traveling through each picking aisle 130A, e.g., the drive wheels 110 of the container bot 110 leading in the direction of movement or drive wheels following in the direction of movement. As may be seen, the outbound throughput from the storage array 130SA in the horizontal plane corresponding to a given storage or deck level 130L is enabled by and manifested in a combined or integrated throughput along both the X and Y throughput axes. As noted above, the container transfer deck(s) 130DC also provide access for the containerbot 110 to each of the lifts 150 at the respective storage level 130L, where the lifts 150 deliver and retrieve case units to and / or from each storage level 130L (e.g., along the Z throughput axis) and the containerbot 110 effects the transfer of the case units between the lifts 150 and the storage space 130S.

[0032] The containerbot 110 may be any suitable independently operable autonomous transport vehicle that, for example, carries and transports / transports case units and / or pick faces (which may be individually or collectively referred to as supply containers 265) and break-pack commodity containers 264, respectively, along the X and Y throughput axes (see FIG. 1B) throughout the storage and retrieval system 100. In one aspect, the containerbot 110 is an automated, independent (e.g., free-riding), autonomous transport vehicle. Suitable examples of bots are described in U.S. Pat. No. 10,822,168, issued November 3, 2020, U.S. Pat. No. 8,425,173, issued April 23, 2013, U.S. Pat. No. 9,561,905, issued February 7, 2017, U.S. Pat. No. 8,965,619, issued February 24, 2015, U.S. Pat. No. 8,965,619, issued April 15, 2014, the disclosures of which are incorporated herein by reference in their entireties for illustrative purposes only. No. 696,010, U.S. Pat. No. 9,187,244 issued November 17, 2015, U.S. Pat. No. 11,078,017 issued August 3, 2021, U.S. Pat. No. 9,499,338 issued November 22, 2016, U.S. Pat. No. 10,894,663 issued January 19, 2021, and U.S. Pat. No. 9,850,079 issued December 26, 2017. The container bot 110 (described in more detail below) may be configured to place case units, such as the retail items described above, into a pick stock at one or more levels of the storage structure 130 and then selectively remove ordered case units. As can be understood, in one aspect, the throughput axes X and Y (e.g., pick face transport axes, see reference frame REFZ in FIG. 1B) of the storage array 130SA are defined by the picking aisle 130A, at least one container transfer deck 130DC, the container bot 110, and the extensible end effector of the container bot 110 (and in other aspects, the extensible end effector of the lift 150 also defines, at least in part, the Y throughput axis).Pick faces (which in one embodiment may include supply containers 265) are transported between an inbound section of storage and retrieval system 100 (e.g., input station 160IN, etc.), where inbound pick faces to the array are created, and a load fill section of storage and retrieval system 100 (e.g., output station 160UT or output station 160EC, etc.), where outbound pick faces from the array are positioned to fill loads according to a predetermined load fill order sequence, or individual fulfillment order(s) according to a predetermined individual fulfillment order sequence. In another embodiment, pick faces (e.g., of supply containers 265) are transported between storage space 130S and a load fill section of storage and retrieval system 100 (e.g., output station 160UT or output station 160EC, etc.) to fill loads according to a predetermined load fill order sequence, or individual fulfillment order(s) according to a predetermined individual fulfillment order sequence. In yet another embodiment, the break-pack commodity container(s) 264 (in one embodiment, multiple break-pack commodity containers can be arranged and transported as pick faces) are transported by the container bot 110 between the storage space 130S and the load filling section, and / or between the break-pack commodity interface 263 of the break-pack module(s) 266 and the load filling section (e.g., output station 160UT or output station 160EC, etc.) of the storage and retrieval system 100 to fill the load according to a predetermined load filling order sequence or the individual fulfillment order(s) according to a predetermined individual fulfillment order sequence. The control server 120 can operate the automated storage and retrieval system 100 in various operational modes such that the pick faces (e.g., of the supply container 265) and the break-pack commodity container 264 are transported to the load filling section according to one or more of the above embodiments to fill the load with one or more of the pick faces (e.g., of the supply container 265) and the break-pack commodity container 264.

[0033] 1B, in one embodiment, the storage structure 130 includes a plurality of storage rack modules RM, the racks being arranged in a three-dimensional array RMA (e.g., forming an array of storage shelves 130SA) in an aisle 130A, the aisle 130A being configured for movement of the container bot 110 within the aisle 130A. The container transfer deck 130DC has a non-deterministic transport surface along which the container bot 110 moves, where the non-deterministic transport surface (also referred to herein as a deck surface) 130BS has a plurality of movement lanes (e.g., more than one juxtaposed movement lane (e.g., a high speed bot movement path HSTP)) for movement of the container bot 110 along the container autonomous transport movement loop 233 (one or more) formed by the container transfer deck 130DC, where the plurality of movement lanes connect the aisle 130A. The container autonomous transport travel loop(s) 233 provide the container bot 110 with random access to any and each picking aisle 130A and to any and each lift 150A, 150B at each level 130L of the storage structure 130. At least one of the plurality of travel lanes has a travel direction opposite to the travel lane direction of another of the plurality of travel lanes (so as to form the container autonomous transport travel loop 233).

[0034] In one embodiment, the storage rack module RM and the container bot 110 are arranged to combine to perform on-the-fly sorting (e.g., such as a pallet output sorting 185 stage) of mixed case pick faces simultaneously with transport along at least one of the throughput axes (or in other embodiments along at least one of more than one) so that two or more pick faces are picked from one or more of the storage spaces and placed in one or more pick face holding locations (e.g., buffer and transfer stations BS, TS, etc.) different from the storage space 130S in accordance with a predetermined load filling order sequence.

[0035] As can be appreciated, any suitable controller of the storage and retrieval system 100, such as, for example, the control server 120, can be configured to create any suitable number of alternate routes or detours for retrieving one or more case units (and / or break-pack goods containers) from their respective storage locations 130S when an aisle provided with access to those case units is restricted or otherwise blocked, in the manner described in U.S. Provisional Patent Application No. 63 / 044,721, filed June 26, 2020, entitled "Warehousing System for Storing and Retrieving Goods In Containers," the entire disclosure of which is incorporated herein by reference.

[0036] It is noted that the storage and retrieval system shown and described herein has only exemplary configurations and in other embodiments may have any suitable configuration and components for storing and retrieving the articles described herein. For example, in other embodiments, the storage and retrieval system may have any suitable number of storage sections, any suitable number of transfer decks, any suitable number of break pack modules 266, and corresponding input / output stations.

[0037] As can be appreciated, the juxtaposed travel lanes are juxtaposed along a common non-deterministic conveying surface 130BS between opposing sides 130BD1, 130BD2 of the container transfer deck 130DC. As illustrated in FIG. 1B, in one embodiment, the aisle 130A is joined to the container transfer deck 130DC at one side 130BD2 of the container transfer deck 130DC, while in other embodiments, the aisle is joined to more than one side 130BD1, 130BD2 of the container transfer deck 130DC in a manner generally similar to that described in U.S. Patent No. 10,822,168, issued November 3, 2020, the entire disclosure of which was previously incorporated herein by reference. As described in U.S. Provisional Patent Application No. 63 / 044,721, filed June 26, 2020, and U.S. Patent Application No. 17 / 358,383, filed June 25, 2021, entitled "Warehousing System for Storing and Retrieving Goods In Containers," the entire disclosures of which have been previously incorporated by reference herein, the other side 130BD1 of the container transfer deck 130DC may include deck storage racks (e.g., interface stations (also referred to as transfer stations) TS and buffer stations BS) distributed along the other side 130BD1 of the container transfer deck 130DC, such that at least a portion of the transfer deck is interposed between the deck storage racks (e.g., buffer stations BS or transfer stations TS) and the aisle 130A. The deck storage rack is positioned along the other side 130BD1 of the container transfer deck 130DC so as to communicate with the container bot 110 from the container transfer deck 130DC and with the lift module 150 (e.g., the deck storage rack is accessed by the container bot 110 from the container transfer deck 130DC and by the lift 150 to pick and place pick faces so that the pick faces are transported between the container bot 110 and the deck storage rack and between the deck storage rack and the lift 150, and thus between the container bot 110 and the lift 150).

[0038] Referring again to FIG. 1A, each storage level 130L may also include a charging station 130C (e.g., positioned at any suitable container transfer location) for charging the on-board power supply of the containerbot 110 at that storage level 130L, such as described in U.S. patent application Ser. No. 14 / 209,086, filed March 13, 2014, and U.S. Patent No. 9,082,112, issued July 14, 2015, the entire disclosures of which are incorporated herein by reference.

[0039] As described herein, with reference to Figures 1A and 2, aspects of the disclosed embodiment provide a break-pack system with optimized containerization and sequencing for end-user (e.g., customer / consumer) requests or order fulfillment for mixed product units or break-pack goods BPG. As described herein, the storage array 130SA has at least one elevated storage level 130L (see Figures 1A and 3A), where mixed product units are entered and distributed (in the manner described herein) into the storage array 130SA in cases of common type product units (e.g., warehouse packs CU) per warehouse pack CU. A customer order 299 (see Figure 2) is an order for mixed product units (e.g., a mix of break-pack goods / vendor packs BPG), each unit of which is stored in the storage array 130SA in cases of common type product units (i.e., unbroken warehouse packs or case units CU) per case. Each of the multiple customer orders 299 is an order for at least one of the mixed product units (i.e., the multiple customer orders 299 include orders for at least one of the mixed product units) (e.g., each customer order 299 includes at least one break pack item / vendor pack BPG).

[0040] An automated transport system 277 (such as those described herein) comprising at least one asynchronous transport system 255A-255n (including at least one container bot 110) for level transport and lifts 150A-150n (such as outbound lift 150B) for transport between storage structure levels 130L is communicatively connected to the storage array 130SA. A respective one of at least one of the lift storage levels 130L may be provided with the asynchronous transport system 255A-255n to automatically retrieve and output product units / break-pack goods BPG distributed to case units CU from the storage array 130SA. The automated transport system 277 may include any suitable number of asynchronous transport systems 255A-255n and lifts 150A-150n (where "n" is an integer representing the upper limit of the range A-n). As described herein, the automated transport system 277 automatically retrieves and outputs from the storage array 130SA the product units BPG that have been distributed to their respective warehouse packs CU in at least one raised storage level 130L of the storage array 130SA. The output product units BPG are output as one or more of mixed individualized products (e.g., individual break-pack items, etc.), mixed pack groups (e.g., two or more break-pack items packed into a break-pack item group in a common container), and mixed cases or warehouse packs CU (e.g., unbroken warehouse packs each having a common type of item).

[0041] At least one asynchronous transport system 255 and lift 150 are configured, at least in part, to form two or more transport channels 260A-260n. Each of the two or more transport channels 260A-260n includes an autonomously guided autonomous bot 110 that asynchronously traverses a picking aisle 130A (of one or more lifted storage levels 130L), a transfer deck 130DC (of one or more lifted storage levels 130L), and each of the at least one lifted storage levels 130L. The bot 110 transports case units CU and / or break-pack commodity containers 264 from storage locations to the lift 150 for output of the case units CU and / or break-pack commodity containers 264 from the storage structure 130 and / or transfer between storage levels 130L. It should be noted that while each autonomously guided autonomous bot 110 is configured to transport one case CU of a common type of product unit from a storage location to a break-pack module 266 and / or from a storage location to a lift 150, etc., each bot is also configured to transport a break-pack product container 264 that holds one or more break-pack products that may be the same type or different types.

[0042] Each of the two or more transport channels 260A-260n also includes a break-pack module 266 input, where break-pack goods are removed from the case units CU and transferred by the goods bot 262 to the break-pack goods containers 264. As described in U.S. Provisional Patent Application No. 17 / 657,705, filed April 1, 2022 and entitled "Warehousing System for Storing and Retrieving Goods in Containers," and U.S. Provisional Patent Application No. 17 / 358,383, filed June 25, 2021 and entitled "Warehousing System for Storing and Retrieving Goods in Containers," the disclosures of which have been previously incorporated by reference in their entireties, the break-pack goods containers 264 are positioned at the put wall 263W, where the container bot 110 retrieves the break-pack goods containers 264 from the storage structure for output. 3A, at least one transport channel 260A-260n is connected to at least one elevated storage level 130L separate and distinct from each of the other transport channels. At least one transport channel 260A-260n is connected to one or more corresponding at least one elevated storage level 130L distinct from the elevated storage level 130L of the storage array / structure 130 connected to each of the other transport channels 260A-260n. For example, each transport channel includes one or more respective storage levels 130L of the storage structure 130 (see FIG. 3A) as described herein and is associated with at least one product group set PGSA-PGSn.

[0043] At least one of the transport channels 260A-260n is separate and distinct from another transport channel 260A-260n. Each transport channel 260A-260n is communicatively connected to at least one raised storage level 130L and to an output of the storage array (e.g., one or more output stations 160UT, etc.). At least one transport channel 260A-260n provides an orthogonal transport output of product units BPG in case units / warehouse packs CU distributed within the storage array 130SA to each of the other transport channels 260A-260n. At least one transport channel 260A-260n is independent of the two or more transport channels 260A-260n such that the output of product units (e.g., case units CU and / or mixed product units BPG held in break-pack commodity containers 264) from at least one transport channel 260A-260n is orthogonal to the output from each of the other transport channels 260A-260n as described herein.

[0044] The controller 120 is communicatively connected to at least one lifting storage and transport level 130L. By the connection of the controller 120 to the at least one lifting storage and transport level 130L, the controller 120 is also communicatively connected to two or more transport channels 260A-260n that include each of the at least one lifting storage and transport level 130L. The controller 120 is configured (i.e., configured with any suitable non-transitory computer program code) to register multiple customer orders (see FIG. 2) of product units (as vendor pack / break pack goods BPG or as whole unbroken warehouse packs CU) and to describe each order with one or more product (goods) groups PGA-PGn of the product units BPG. Each product group PGA-PGn has unique predefined product group characteristics that characterize the product groups PGA-PGn and relate the product groups PGA-PGn to each other. In another aspect, the controller 120 is configured to register a customer order 299 for a product unit BPG that is characterized by one or more product groups PGA-PGn of the product unit BPG, where each product group PGA-PGn has unique predefined product group characteristics that characterize the product unit BPG of the product group PGA-PGn and that relate the product group PGA-PGn to each of the other product groups PGA-PGn.

[0045] The unique predefined product group characteristic may be one or more of product type (e.g., toothpaste, deodorant, shaving cream, footwear, bakeware, cleaner, etc.), structural characteristics of the product (e.g., fragility of the product or product packaging, etc.), similarity of one product to another according to store rules (as described herein), and any other suitable characteristic, where the relationships between product groups PGA-PGn arise from the grouping of product groups PGA-PGn by commodity category (and their unique predefined product group characteristics, e.g., corrosive products are placed below non-corrosive products, products are stacked or otherwise containerized with the most fragile products on top and the least fragile products on the bottom, etc.) and inform or otherwise define the merging potential of the commodity categories. Grouping of product categories (e.g., based on rules and / or predetermined characteristics) in product group sets PGSA-PGSn at a given storage level or levels 130L includes many break-pack products BPG in fewer product group sets PGSA-PGSn such that there is a bias towards merging of product categories into product group sets PGSA-PGSn that span multiple customer orders (e.g., separate from customer orders). According to aspects of the disclosed embodiment, there is a maximization of product categories into product group sets PGSA-PGSn, and accordingly, each product group set PGSA-PGSn includes a maximum or optimal number of product categories.

[0046] The controller 120 is also configured to heuristically resolve the product groups PGA-PGn of two or more orders into product group sets PGSA-PGSn based on the product group characteristics. In another aspect, the controller 120 dynamically resolves the product groups PGA-PGn describing each customer order 299 into product group sets PGSA-PGSn via a heuristic solution based on the product group characteristics (which are unique and predetermined as described herein). Each product group set PGSA-PGSn is from the multiple product groups PGA-PGn, is orthogonal to each of the other product group sets PGSA-PGSn, and has a maximum number of product groups PGA-PGn that can be merged. The controller is configured to dynamically combine, within predetermined boundaries (e.g., break pack container 264), product units BPG of assigned product group sets PGSA-PGSn of at least one lifting storage and transport level 130L (or transport channels 260A-260n) into batches of mixed product units BPG for each customer order 299 corresponding to the assigned product group sets PGSA-PGSn using another heuristic solution as described herein with respect to the containerization process. The other heuristic solution is based on at least one product group characteristic and customer or default similarity rules as described herein.

[0047] The controller 120 is configured to dynamically partition the product group sets PGSA-PGSn based at least on the amount of the assigned product group set PGSA-PGSn relative to a predetermined threshold (e.g., average vendor pack requirement of Equation 2A or Equation 2B) of product units (e.g., vendor pack / break pack product PEG) transported via at least one transport channel 260A-260n and the amount of each of the other assigned product group sets PGSA-PGSn (e.g., assigned to the other transport channels 260A-260n) relative to each of the other transport channels 260A-260n's respective thresholds (e.g., average vendor pack requirement of Equation 2A or Equation 2B). Each of the partitioned product group sets PGSA-PGSn is orthogonal to each of the other product group sets PGSA-PGSn and has a maximum number of complementary, similar (e.g., similarity characteristics as described herein), and / or mergible product groups PGA-PGN.

[0048] The product group set(s) PGSA-PGSn are dynamically assigned for pick-up and output of the product units BPG forming the product group sets PGSA-PGSn via at least one storage and transport level 130L to an order container (e.g., break pack container 264) holding a batch of mixed product units BPG, where the product group sets are dynamically assigned such that a predetermined threshold (e.g., average vendor pack requirement of Equation 2A or Equation 2B) of product units BPG transported via at least one storage and transport channel 260A-260n is not exceeded. If a predefined threshold (for a given delivery channel) is exceeded (it is noted that the predefined threshold, which seeks to balance transactions between storage levels or delivery channels for maximizing throughput of the storage and retrieval system 100 as described further herein, is a dynamic factor that varies depending on the orders filled by each delivery channel and new orders received (e.g., the demand for order(s) per delivery channel versus transaction output per channel) to enable dynamic recovery of balanced transactions), the product group(s) of the product group set may be dynamically reallocated to another delivery level (see FIG. 2) where the product units being delivered are below the predefined threshold. Since the reallocation is based on product blendability, taking into account the orthogonality of the delivery levels, the products reallocated to other levels may be selected for inclusion in the product group set (instead of packages of the same product placed in the level to which they were originally assigned), if such a selection results in a more efficient product output of the respective delivery channel and product group set. Here, the reallocation is based on what is called the highest fillability (e.g., determined by the average vendor pack of the highest current delivery channel compared to the average vendor pack for the other levels).In one or more embodiments, the controller 120 is configured to effect dynamic allocation of the separated product group sets PGSA-PGSn to at least one transport channel 260A-260n (and / or its at least one lift storage and transport level 130). The controller may also be configured to balance the product group sets PGSA-PGSn assigned to at least one transport channel 260A-260n with other assigned product group sets PGSA-PGSn assigned to each of the other transport channels 260A-260n (e.g., to provide a substantially probabilistic distribution of case units / products according to customer rules that are decoupled from, but aligned (if not aligned) with, customer rules, as described herein).

[0049] For example, upon input of a warehouse pack CU into the storage and retrieval system 100, the warehouse pack CU is assigned / separated or otherwise formed into one or more product group sets or work groups PGSA-PGSn. Each product set PGSA-PGSn includes one or more product groups PG of product groups PGA-PGn. Each of the one or more product groups PG, PGA-PGn, is dynamically assigned, such as by the controller 120, to a respective storage level 130L, 130L1-130L3. At least one of the separation of product group sets PGSA-PGSn and the assignment of product group sets PGSA-PGSn minimizes the bot 110 transport of case CUs of product units (including break-packed merchandise containers 264) per customer order 299. For example, separating the product group sets PGSA-PGSn provides for the possibility of blending products with one another, for example in the break pack module 266, so that one case unit of product is included in multiple break pack goods containers 264 of a batched customer order 299C, minimizing the number of trips for a particular case unit. Dynamic allocation (and / or dynamic reallocation (see FIG. 2)) of the product groups PGA-PGn to the various storage levels 130L distributes the product transport load substantially evenly (in a substantially probabilistic distribution as described herein) among the storage levels 130L, reducing the number of trips required by the containerbot 110 to transport case units for any given order (as described herein). Warehouse packs CU may be assigned to the product groups PG of the respective product group sets PGSA-PGSn in any suitable manner, such as by any suitable product characteristics, including, but not limited to, those described herein.

[0050] At least one of separating the product group sets PGSA-PGSn and allocating the product group sets PGSA-PGSn optimizes the transport of product units (e.g., case units CU and / or break-pack goods BPG) by the asynchronous transport system 255A of the respective transport channels 260A-260n per customer order 299. For illustrative purposes, each product group set PGSA-PGSn may correspond to a customer (or a group of similar customers) and the product groups PGA-PGn may correspond to goods sold / distributed by the customer. The product groups PG, PGA-PGn are generated by the controller 120 to bias the placement of the warehouse packs CU in the storage array 130SA such that the break-pack goods BPG held in the warehouse packs CU are known to be blendable with each other in a common shipping container (e.g., can be packed together according to a predetermined criteria as described herein). For example, the controller 120 may group the warehouse packs CU based on similarity rules and / or any other suitable criteria (including, but not limited to, product type, product structure characteristics, etc., as described herein) applied at each storage level 130L. Here, the product groups PG, PGA-PGn are divided into any suitable number of operating zones based on any suitable criteria (similarity rules, product type, etc.) such that the products in the warehouse packs CU of each product group PG are processed orthogonally in the respective operating zones. The generation of the product groups PGA-PGN and product group sets PGSA-PGSn exploits the aggregation or availability (e.g., distribution of warehouse packs CU in the storage array 130SA in a substantially stochastic distribution) of many product groups PGA-PGn (e.g., commodity categories) of one or more customers at the storage level to optimize the fusion probability of products in any given order.Formation of product group sets PGSA through PGSn as described herein biases fusion probability to maximize the number of fusion-possible commodity categories (or product groups PGA through PGn) into product group sets PGSA through PGSn, where the controller iteratively processes the commercial categories to result in a substantially probabilistic distribution according to customer rules that are separate from, but consistent with (if not consistent with) the customer rules (see Figures 4A-4C and 5A-5F).

[0051] In the example described herein, the operating zones each correspond to one or more storage levels 130L, but in other embodiments, there may be two or more zones operating on each storage level 130L. By way of example, the controller 120 is configured to assign warehouse packs CU to each storage level 130L based on criteria including, but not limited to, the number of break-pack items for a given customer order and the blendability of the break-pack items BPG. With respect to the number of break-pack items for a given customer order, the picking / transport load is allocated evenly across or between the storage levels 130L. With respect to the blendability of break-pack items (e.g., of one product category) with other break-pack items (e.g., of another product category), the adjacency of the product categories is maximized such that the fill of the shipping container is maximized and the number of shipping containers is minimized. Product category adjacency may be based on store similarity rules, such as those described in U.S. Provisional Patent Application No. 63 / 288,253, filed December 10, 2021, entitled "Material Handling System and Method Therefor," the entire disclosure of which is incorporated herein by reference, and / or any other suitable criteria (as described herein, including but not limited to product type, product construction characteristics, etc.).

[0052] Product category adjacency can enable "store-ready" pallets PALs output from the automated storage and retrieval system 100, where "store-ready" refers to the store-likeness or pallet-load-store-likeness of the pallet load, whereby the pallet-load configuration (i.e., pallet-load build) includes predetermined characteristics (or factors) of store-likeness that bias or factor the classification of each resulting pallet-load PALO according to and to provide it with a retail store characteristic that conforms to or is aligned with the predetermined characteristics of the retail store. For example, when the pallet-load PALO(s) of a fulfilled mixed product order (see "Order" in FIG. 2) arrives at the ordering store or customer 200, the pallet-load PALO(s) can be quickly unloaded (e.g., following "just-in-time" inventory management practices) and the products distributed (e.g., restocked / stocked) to the store shelves 233 with minimal disruption to store operations. To facilitate rapid unloading and delivery of goods to store shelves 233, the storage and retrieval system 100 is configured to structure the pallet load(s) PALO such that the structure of goods on the pallet load(s) PALO (e.g., individualized products (e.g., individual break-pack items) in a mixed pack group (e.g., two or more break-pack items packaged in a group of break-pack items in a common container), and mixed case or warehouse pack CUs (e.g., unbroken warehouse packs each having a common type of item)) are grouped in a manner similar to the way the goods CUs are distributed to store shelves 233.

[0053] It is noted that each of the one or more pallet loads PALO in the mixed product order 299 is constructed by the automated storage and retrieval system 100 such that each pallet load PALO is a "store-ready pallet" or a "store-ready pallet load." For example, when the pallet load PALO(s) of a fulfilled mixed product order 299 (see FIGS. 7-9 ) arrives at the order store 700, the pallet load PALO(s) (e.g., pallet load PALOC in FIG. 7 , PALOA, PALOA' in FIG. 8 , and PALOC, PALOC' in FIG. 9 ) is quickly unloaded (e.g., in accordance with "just-in-time" inventory management practices) and the goods are distributed (e.g., restocked / stocked) to the store shelves 733 with minimal disruption to store operations. To facilitate rapid unloading and delivery of goods to store shelves 733, the automated storage and retrieval system 100 is configured to structure the pallet load(s) PALO such that the structure of goods CUs (also referred to herein as packages, products, case units, mixed cases, cases, shipping cases, shipping units) on the pallet load(s) PALO are grouped in a manner similar to the way goods CUs are distributed to store shelves 733.

[0054] Each warehouse customer (e.g., order store 200) of the warehouse 199 may have its own preferences for handling pallet loads within the order store 200. Aspects of the present disclosure provide for building store-enabled pallets that correspond to various ways in which warehouse customers handle pallet loads and distribute products. These various ways in which pallet loads are handled and products are distributed are referred to as order store similarity characteristics. These order store similarity characteristics (e.g., predetermined customer similarities) are one or more of a clustered aisle pallet load package distribution method (e.g., see FIG. 7), an adjacent aisle pallet load package distribution method (e.g., see FIG. 8), and a mixed-mode clustered and adjacent aisle pallet load package method (e.g., see FIG. 9). The order store similarity characteristics (one or more) may be stored in any suitable memory, such as a memory of the control server 120 and / or palletizer of the output station 160UT, and may be utilized by the control server 120 and / or the output palletizer to generate the pallet load PALO described herein.

[0055] With reference to FIG. 7, one exemplary method for handling palletized loads PALO may be referred to as a "clustered aisle palletized load package distribution method" and includes dismantling / unloading the palletized load(s) PALOC at the loading dock area 722 (or other suitable area) of the order store and placing the goods CU belonging to different sections of the order store 200 onto two or more separate secondary pallets PAL21-PAL23 (three secondary pallets are shown in FIG. 7 for illustrative purposes). These secondary pallets PAL21-PAL23 contain goods CUs assigned to a given shopping aisle and are moved to each given shopping aisle for unloading (see FIG. 7). When each shopping aisle has secondary pallets PAL21-PAL23, the goods CUs from the secondary pallets PAL21-PAL23 are distributed to the assigned shelves 733.

[0056] With reference to FIG. 8, another example of handling pallet loads PALO may be referred to as an "adjacent aisle pallet load package distribution method" and includes moving the entire pallet load PALOA, PALOA' to the shopping aisle (e.g., without loading or unloading the pallet). When the pallet load PALOA, PALOA' is in the shopping aisle, the goods CU are distributed substantially directly from the pallet load PALOA, PALOA' to the assigned shelf 733 (see FIG. 8). Here, the goods are placed on the pallet load(s) PALOA, PALOA' in a manner that minimizes the travel distance of each pallet load PALOA, PALOA' in the store and substantially avoids the pallet PALOA, PALOA' returning to an aisle previously visited by the corresponding pallet (e.g., the pallet passes through the aisle only once along a predetermined path 801, 802). The goods CU may be placed on the pallet load PALO, PALOA' according to the path 801, 802 of movement of the respective pallet load PALOA, PALOA' through the shopping aisle.

[0057] With reference to Fig. 9, yet another example of pallet PALO may be referred to as a "mixed mode clustered and adjacent aisle pallet load package distribution method" and includes a combination of the above handling methods. With reference to Fig. 9, pallet loads PALOC, PALOC' arrive at the order store 200 by truck (or other suitable transportation means) from the warehouse / distribution center 199. The pallet loads PALOC, PALOC' are moved (without unloading the pallet) to a shopping area generally proximate to the shelf to which the products CU on the pallet loads PALOC, PALOC' are assigned. With the pallet loads PALOC, PALOC' generally located near the assigned shelf, the pallet loads PALOC, PALOC' are unloaded onto the respective secondary pallets PALO21, PALO22, PALO23, PALO21', PALO22' assigned to the respective shopping aisle. Here, the pallet loads PALOC, PALOC' are constructed such that each pallet load PALOC, PALOC' includes goods belonging / assigned to store aisles that are adjacent to one another (e.g., pallet load PALOC includes goods located in aisle 1, aisle 2 (adjacent to aisle 1), and aisle 4, which is one aisle away from aisle 2; similarly, pallet load PALOC' includes goods belonging / assigned to adjacent aisles 12 and 13). Goods CU may also be arranged within each pallet load PALOC, PALOC' such that the pallet structure matches the way goods are loaded / unloaded onto each secondary pallet (e.g., sequential loading / unloading, where goods assigned to secondary pallet PALO21 are at the top of the pallet structure of the pallet load PALOC, goods assigned to secondary pallet PALO22 are in the middle of the pallet structure of the pallet load PALOC, goods assigned to secondary pallet PALO23 are at the bottom of the pallet structure of the pallet load PALOC, etc.). In this embodiment, the aisles to which the products CU are assigned do not have to be located along respective specific routes (e.g., see routes 801, 802 in FIG. 8 ) for unloading the products CU of each pallet load PALO, PALO' onto store shelves.

[0058] The above examples of pallet handling / unloading methods at the order store 200 are merely illustrative. It is again noted that the pallet load PALOC, PALOC', PALOA, PALOA' for each of the pallet handling / unloading methods are generally referred to herein as the pallet load PALO. It is also noted that the pallet load PALO(s) may be constructed in any suitable manner by the automated storage and retrieval system 100 such that the goods on the pallet load PALO(s) are arranged according to at least one order pallet and order store similarity characteristic (which may include goods arrangement based on product type, product structural characteristics, etc.) for the pallet load package distribution method described herein. It is noted that the pallet load disassembly of the order store similarity (as described herein) is decoupled from the arrangement of the storage array 130SA and the throughput of the material handling system 190 of the case CU to the palletizer 162. Here, the output of the case CU from the storage array 130SA by the automated transport system 277 is selected to follow or otherwise depend (based on) the pallet load disassembly of the order store similarity. In one or more embodiments, the throughput of case CUs output by the material handling system 190 can be enabled in a manner similar to that described in U.S. Patent Application No. 17 / 091,265, filed November 6, 2020, entitled "Pallet Building System with Flexible Sequencing," the entire disclosure of which is incorporated herein by reference. According to embodiments of the present disclosure, the placement of case CUs within the storage array 130SA can be freely optimized for optimal throughput, separate from the disassembly and construction of pallet loads PALOs of similar order stores. An example of throughput optimization can be found in U.S. Patent No. 9,733,638, issued August 15, 2017, entitled "Automated Storage and Retrieval System and Control System Thereof," the entire disclosure of which is incorporated herein by reference.

[0059] As an example of the formation / generation of product group sets PGSA-PGSn, referring to FIGS. 3A, 4A-4C, 5A-5F, and 6, the controller may dynamically assign product group sets PGSA to storage levels 130L1, 130L2, 130L3 based on any suitable criteria, such as customer ID. Referring to FIG. 6, all items / stock keeping units (e.g., case units CU or warehouse packs WHPK and stock keeping units SKUs held therein) placed in pick stock in storage array 130SA are assigned a commercial category (personal hygiene products, household products, cleaners, etc.) and a commercial department number that occur as characteristics of the pick order. In FIG. 6, SKU (stock keeping unit) represents the ID of case unit CU, WHPK / VNPK are the vendor packs required for each SKU for a batch of orders 299 (e.g., consolidated order 299C), DEPT is the customer department number, and CAT is the product category. Based on the characteristics of the pick order (e.g., commercial category and commercial department number), the case unit CU is divided into product groups as described below. As described below, the vendor packs required for each article is a metric utilized by the controller 120 in combination with a known number of vendor packs required for a batch of orders (e.g., customer orders are consolidated into batches (see FIG. 2 )) to distribute the vendor packs BPG within the case unit CU substantially evenly among storage levels 130L based on the constraint that a product category or department cannot be distributed across multiple levels.

[0060] Warehouse pack CU having product categories A, B is assigned to product groups PGA, PGB on storage level 130L1 (e.g., based on the fusion potential of the product categories). Warehouse pack CU having product categories B, C is assigned to product groups PGB, PGC on storage level 130L2 (e.g., based on the fusion potential of the product categories). Warehouse pack CU having product category D is assigned to product group PGD on storage level 130L3 (e.g., based on the fusion potential of the product categories). Controller 120 is configured to effect work grouping (e.g., formation of product group sets PGSA-PGSn) in any suitable manner, such as the example manners illustrated in FIGS. 4A-4C.

[0061] As an example, a product input includes case units CU A, B, B', C, and D, where case unit A belongs to product category A, case units B, B' belong to product category B, case unit C belongs to product category C, and case unit D belongs to product category D (see also Figs. 5A-5G, where A, B, B', C, and D represent not only product categories but also case units of that product). The controller 120 is configured to loop through / determine all case units CU of product categories (e.g., product categories A-F, herein) of the product input that are not assigned to a level or need to be reassigned (see Fig. 2) to various levels (Fig. 4A, block 401). The controller 120 also determines, for a given pick level 130L, whether there are product categories already assigned to each of the pick levels 130L (Fig. 4A, block 402). If pick level 130L does not have a product category assigned to it, the controller assigns a product category to the pick level (FIG. 4A, block 403). For example, storage level 130L1 is determined by the controller to have no product category associated with it, and case units for product category A are assigned to storage level 130L1 by controller 120 (see FIGS. 5A and 5B), and the controller returns to FIG. 4A, block 401.

[0062] If a product category exists in the storage level 130L (FIG. 4A, block 402), the controller 120 determines whether the product category of the product input can be merged with the product category of the pick level (FIG. 4A, block 404). For example, product category A is assigned to pick level 130L1, and the controller 120 has made a level assignment for product category / case unit B of the product input. Here, the controller 120 determines (e.g., based on criteria described herein) that product category / case unit B can be merged with product category A. The controller 120 determines whether the number of break-pack products / vendor packs required in a case unit of product category B (VNPK RQD) for a batch of orders (i.e., combined customer orders) plus the number of break-pack products BPG of product category B already present in storage level 130L1 (VNPK CURRENT) is less than or equal to a predetermined average vendor pack (AVG VNPK) for each storage level (FIG. 4A, block 405) (see Equation 1 below). VNPK RQD + VNPK CURRENT <= AVG VNPK * [Formula 1] Here, the average vendor pack may be referred to as a threshold defined as follows: AVG VNPK = (CO ORD×BPG CASE) / NUM LVLS [Formula 2A] Where CO ORD is the number of case units CU to be ordered, BPG CASE is the number of break pack items per case unit, and NUM LVLS is the storage level or or AVG VNPK = TTL CASES / TTLNUM VNPK [Formula 2B] where TTL CASES is the total number of case units in storage for a given break pack item and TTLNUM VNPK is the total number of case units in storage for a given break pack item. The required break pack item per vendor pack (VNPK RQD) is equal to the total warehouse pack orders (TWPQO) for the item divided by the warehouse packs per vendor pack (WPVP) for the item as shown in Equation 3 below. VNPK RQD = TWPQO / WPVP * [Formula 3] Now, if equation 1 is satisfied, the controller adds the case unit for the product category (in this example, product category / case unit B) to the storage level (in this example, storage level 130L1) (Figure 4A, block 403 (see Figures 5B and 5C)) and the controller returns to Figure 4A, block 401.

[0063] *As previously mentioned, with respect to equations 1 and 3 above, as can be understood, the average vendor pack is a dynamic coefficient that varies with the orders fulfilled by each delivery channel and new orders received (e.g., demand for order(s) per delivery channel relative to transaction output per channel) to enable dynamic recovery of balanced transactions.

[0064] For product category B, there may be another case unit B' that is assigned to the storage level. If equation 1 is not satisfied, then the controller 120 determines whether the assigned product category is the last product category eligible to be merged into the workgroup (which in this example is the workgroup made up of product groups / product categories in storage level 130L1) (FIG. 4B, block 406). If the assigned product category is the last product category eligible to be merged into storage level 130L1 (FIG. 4B, block 406), then the assigned product category is assigned to storage level 130L1 (FIG. 4A, block 403) and the controller returns to FIG. 4A, block 401 (see FIG. 5C). If the assigned merchandise category is not the last merchandise category eligible to be grouped with the merchandise category at storage level 130L1 (FIG. 4B, block 406), controller 120 determines whether the assigned merchandise category can be merged with other merchandise categories not assigned to the pick level (FIG. 4B, block 407; e.g., in the example provided, merchandise category B could also be merged with unassigned merchandise category C). If the assigned merchandise category can be merged with an unassigned merchandise category, controller 120 determines whether (see FIG. 4B, block 409): VNPK ADDED + VNPK CURRENT <= AVG VNPK + VAR [Formula 4] where VAR is a predetermined percentage by which the average vendor pack AVG VNPK can be increased for a given storage level. VAR can be the same for one or more storage levels 130L and different for one or more other storage levels 130L. If Equation 4 is satisfied, unit B' is added to storage level 130L (FIG. 4A, block 413 (see FIG. 5C)). If Equation 4 is not satisfied, the assigned product category (in this example, product category B and case unit B') is assigned to the next available storage level (FIG. 4C, block 410 (see FIG. 5D)).

[0065] If the assigned product category is not blendable with the unassigned product category (FIG. 4B, block 407), e.g., product category C is not blendable with product category D, the controller 120 determines whether the product category cannot be blended with other product categories and can be added to a pick level based on the average vendor pack requirements (FIG. 4B, block 408). If the non-blendable product category C can be added to a pick level (e.g., pick level 130L2) according to the average vendor pack requirements, the non-blendable product category is added to that pick level (FIG. 4A, block 403 (see FIGs. 5D and 5E)).

[0066] With respect to product category / case unit D, for illustrative purposes only, product category D cannot be blended with other product categories assigned to a storage level (FIG. 4A, block 404), cannot be blended with product categories not assigned to a storage level (FIG. 4B, block 407), and cannot be added to a storage level based on average vendor pack requirements (FIG. 4B, block 408). Here, the controller has assigned product category / case unit D to the next storage level (which in this example is storage level 130L3).

[0067] In Figure 4C, block 411, the controller 120 determines whether the storage level to which the product categories were assigned in Figure 4C, block 410 is the last storage level. If it is not the last storage level, the controller 120 returns to Figure 4A, block 401. If it is, the controller 120 assigns the remaining product categories to the last pick level (Figure 4C, block 412).

[0068] Once the product group sets PGSA-PGSn are generated, the automated transport system 277 transports the warehouse packs CU to the assigned storage spaces 130S of the assigned storage level 130L for customer order fulfillment. With the product groups PGA-PG of the product group sets PGSA-PGSn arranged in the storage array 130SA, the controller 120 is also configured to assign each of the separated product group sets PGSA-PGSn to at least one transport channel 260A-260n for retrieval and output of the product units BPG forming the product group sets PGSA-PGSn to the mixed product unit order container via the at least one transport channel 260A-260n, where the product group sets PGSA-PGSn are assigned such that the product units transported via the at least one transport channel 260A-260n do not exceed a predetermined threshold (e.g., the average vendor pack requirement of Equation 2A or 2B). For example, when a customer order 299 is received and fulfilled, the controller 120 causes operation of the asynchronous transport system 255A associated with each product group set PGSA-PGSn such that each transport channel 260A-260n picks up and outputs the ordered products orthogonal to each of the other transport channels 260A-260n.

[0069] As an example of an orthogonal output of the conveying channels 260A-260n, the products output by each conveying channel 260A-260n are orthogonally output as an output product set. The output product set of each conveying channel 260A-260n is a closed set of merged product categories (e.g., product groups) closed within the respective conveying channel 260A-260n, where the closed set of merged product categories is separate from and does not incorporate product categories / products from any other output product set of any other conveying channel 260A-260n. The output product set of each conveying channel may be referred to as an output stream of products, where a stream from one conveying channel 260A-260n does not depend on, incorporate, or intersect with any other stream from any other conveying channel 260A-260n.

[0070] 10, with the product group sets PGSA-PGSn separated and the product groups PG, PGA-PGn arranged in the storage array 130SA (see, for example, FIGS. 2, 3A, and 5A-5F), the controller 120 effects the containerization of the mixed product units according to the orders 299 of the individual stores / customers 200. As seen in FIG. 10, the customer orders 299 (illustrated as four customer orders being batched as a consolidated order 299C, corresponding to the orders of customers X, Y, A, and B also illustrated in FIG. 10) are received at / by the controller 120. It is noted that the containerization of the product units of the order 299C is virtually performed by the controller 120 prior to the transportation of the product units from the storage location. Once the containerization of the product units is virtually planned, the controller 120 enables the sequencing of the product units (as described herein) for transportation and physical containerization according to the predefined containerization plan.

[0071] To effect the containerization plan, the controller 120 divides the consolidated order 299C into waves or order segments 299CS, each segment corresponding to one or more customers and serviced by a respective transport channel 260A, 260B. The consolidated order 299C may be divided based on any suitable criteria, such as, for example, a comparison between one or more of the product groups included in the order for each customer, the product groups placed in the storage array 120SA, and the store planograms for the customer stores.

[0072] Once the consolidated order 299C is split into order segments 299CS, the controller applies any suitable containerization algorithm to the order segments 299CS. Examples of containerization algorithms include, but are not limited to, a first fit algorithm and a best fit algorithm. For a first fit algorithm, the controller 120 plans the placement of products in a container (e.g., break-pack commodity container 264, etc.) in any suitable predefined order / fill order (including, but not limited to, ordering based at least in part on rules that place products in a container according to product type characteristics (e.g., corrosive materials under non-corrosive materials, etc.) and / or product construction characteristics (e.g., least fragile products at the bottom of the container, etc.), as described below), until the next item of a given order does not fit in the container. Here, the controller 120 closes the container (even if the container is not full) and places the next item in the next subsequent container. For a best fit algorithm, the controller plans the placement of products in a container in any suitable predefined order / fill order until the container is filled. A containerization algorithm may be specified by customer 200, in which case the specified containerization algorithm is also taken into consideration when splitting consolidated order 299C into order segments 299CS.

[0073] The controller 120 schedules the allocation of products in the order segment 299CS to respective customers 200 for fulfillment at the break pack station 266, where break pack goods / vendor packs BPG are removed from the case units / warehouse packs CU and transported by the goods bots 262 to the break pack containers 264 (located at the put wall 263W) (see FIG. 1A) according to the containerization rules 264R. The containerization rules 264R include, but are not limited to, placing the products in the break pack goods containers 264 according to one or more of the following: similarity between products (e.g., as described herein with respect to the store planogram), item / product characteristics (e.g., product type; food should not be mixed with perishables, perishables are placed below non-perishables, least perishable products are at the bottom of the container, etc.), pick eligibility and pick station rates for the items (e.g., manual picking vs. robotic picking), customer-specified product grouping order, and department segregation (e.g., products from one department in the store are not mixed with products from another department in the store). As mentioned above, the outputs of the transport channels 260A-260n are orthogonal such that the various transport channels 260A-260n and the various customer containerizations of the various transport channels may employ different containerization rules based, for example, on customer order requirements. Also, the break-pack commodity containers 264 may include different types of containers (e.g., leak-proof containers, ventilated containers, etc.) that are placed at the pick wall, where product units are placed in the different types of containers (e.g., perishable goods are placed in leak-proof containers and food products are placed in ventilated containers to preserve freshness) based, for example, on customer requirements and / or product group requirements.

[0074] 11A-11D, an exemplary containerization (also called cartonization) process is described. The controller 120 is configured to optimize containerization of ordered products (e.g., in three dimensions) in a manner that can be differently configured for different automated storage and retrieval systems 100 and different customers 200 of each automated storage and retrieval system 100. Containerization is the process of grouping / placing ordered products into bounded areas (e.g., containers 264) to minimize the associated costs incurred in placing the products in the containers 264.

[0075] The controller 120 is configured to loop through all customers 200 whose orders are batched together in the consolidated order (FIG. 11A, block 1102). For example, and referring also to FIG. 10, the controller 120 determines that the consolidated order 299C includes product units ordered by customers X, Y, A, and B. The controller 120 determines whether any of the customers X, Y, A, or B have ordered product units that remain unprocessed (FIG. 11A, block 1103). If all of the ordered product units for all of the customers have been processed, the containerization process is complete (FIG. 11A, block 1122). In this example, because product units remain outstanding for customers X, Y, A, and B, the controller 120 sorts pick orders (e.g., ordered product units) for each customer (e.g., use customer X) based on customer product category adjacency (or default customer product category adjacency if the customer does not specify adjacency) and descending order of product unit volume and weight for each customer X, Y, A, and B ( FIG. 11A , block 1104).

[0076] The controller 120 loops through the non-containerized pick order lines (e.g., items in a customer order) (in order) (FIG. 11A, block 1105) and determines whether any open order lines remain in the order line sequence (FIG. 11B, block 1106). If there are no additional order lines for a customer (e.g., customer X), the controller 120 closes the existing open containers 264 for the customer (FIG. 11B, block 1124) and returns to block 1102 to process ordered product units for the remaining customers (e.g., customers Y, A, B). If there are order lines remaining open, e.g., for customer X, the controller 120 determines whether there are any open containers 264 assigned to the customer (FIG. 11B, block 1107). If there are no open containers, the controller 120 opens and assigns a container 264 to the customer (FIG. 11B, block 1116), adds the next pick order line in the pick order line order to the container 264 (FIG. 11B, block 1123), and returns to block 1105 to process the next subsequent pick order line in the pick order line order, for example, for customer X.

[0077] For example, if there is an open container 264 assigned to customer X, the controller determines whether the goods corresponding to the pick order line can fit into the container 264 based on the customer product mix rules (as described herein) or default product mix rules if no customer rules are specified ( FIG. 11B , block 1108). As described above, a customer can specify rules for containerization (e.g., mix departments, do not mix departments, mix product categories, do not mix product categories, etc., taking into account rules regarding product characteristics such as location of corrosive products relative to location of non-corrosive products in the container and product fragility), but if the customer does not provide / specify rules for containerization, the default product mix rules (which may allow mixing of products for different departments and / or commodity categories, taking into account rules regarding product characteristics such as location of corrosive products relative to location of non-corrosive products in the container and product fragility) are applied to the containerization for that customer.

[0078] If the product in the pick order line fits into the container 264, the controller determines whether the item fits into the container based on any customer specified product category adjacency rules (or if no category adjacency is specified by the customer, default category adjacency rules where product categories are mixed together are applied) (FIG. 11B, block 1109). If the product does not fit into the container 264 based on the customer or default product category adjacency rules, the controller 120 closes the existing open container 264 for the customer (FIG. 11B, block 1117), opens a new container 264 (FIG. 11C, block 1116), and adds the product for the pick order line to the new container (FIG. 11B, block 1123). The controller 120 proceeds to block 1105 to process the next subsequent pick order line in the pick order line order.

[0079] If the controller determines that the product for the pick order line fits into the container based on customer specified (or default) product category adjacency rules (e.g., and any rules regarding product characteristics such as location of corrosive products relative to location of non-corrosive products in a container and fragility of the product), the controller determines whether the warehouse pack CU fits into the container 264 based on volume and weight (FIG. 11C, block 1110). If the warehouse container CU fits into the container, the controller adds the product for the pick order line to the container 264 (FIG. 11D, block 1115) and returns to block 1105 to process the next subsequent pick order line in the pick order line sequence.

[0080] If the controller determines that the warehouse pack CU does not fit into the container 264 based on volume and weight, the controller 120 determines whether the volume or weight of the warehouse pack CU is greater than the volume and weight of the empty container 264 (FIG. 11C, block 1111). If the volume or weight of the warehouse pack CU is greater than the volume or weight of the empty container 264, the controller determines whether the quantity of the product in the order line is greater than one (FIG. 11C, block 1118). If the ordered quantity of the product is not greater than one, the controller 120 marks the product as an exception product that cannot fit into the container (FIG. 11C, block 1119) and returns to block 1105 to process the next subsequent pick order line in the pick order line sequence.

[0081] If the ordered quantity of the product is greater than one, the controller 120 determines whether the container 264 is empty (FIG. 11C, block 1120). If the container 264 is empty, the controller 120 divides the volume of the container 264 by the quantity of the product ordered (FIG. 11C, block 1121) and returns to block 1110. If the container 264 is not empty, the controller 120 determines whether there is a product in the container 264 that meets the product mix and adjacency rules with respect to the product in the pick order line being analyzed (FIG. 11C, block 1113 and FIG. 11D, block 1114). If there is a product in the container that meets the mix / adjacency criteria, the controller 120 adds the product in the pick order line to the container 264 and returns to block 1105 to process the next subsequent pick order line in the pick order line order. If there are no products in the container that meet the mix / adjacency criteria, the controller 120 closes the existing container 264 for the customer (FIG. 11B, block 1117), opens a new container 264 (FIG. 11C, block 1116), and adds the products for the pick order line to the new container (FIG. 11B, block 1123). The controller 120 proceeds to block 1105 to process the next subsequent pick order line in the pick order line sequence.

[0082] If the controller determines that the warehouse pack CU does not fit into the container 264 based on volume and weight (FIG. 11C, block 1110) and the volume or weight of the warehouse pack CU is not greater than the volume and weight of the empty container 264 (FIG. 11C, block 1111), the controller determines whether a best fit algorithm is employed to containerize the products (FIG. 11C, block 1112). If a best fit algorithm is employed, the controller 120 determines whether there are products in the container 264 that meet the product mix and adjacency rules with respect to the products in the pick order line being analyzed (FIG. 11C, block 1113, and FIG. 11D, block 1114). If there are products in the container that meet the mix / adjacency criteria, the controller 120 adds the products in the pick order line to the container 264 and returns to block 1105 to process the next subsequent pick order line in the pick order line order. If there are no products in the container that meet the mix / adjacency criteria, the controller 120 closes the existing container 264 for the customer (FIG. 11B, block 1117), opens a new container 264 (FIG. 11C, block 1116), and adds the products for the pick order line to the new container (FIG. 11B, block 1123). The controller 120 proceeds to block 1105 to process the next subsequent pick order line in the pick order line order. If the best fit algorithm is not employed, the controller closes the existing container 264 for the customer (FIG. 11B, block 1117), opens a new container 264 (FIG. 11C, block 1116), and adds the products for the pick order line to the new container (FIG. 11B, block 1123). The controller 120 proceeds to block 1105 to process the next subsequent pick order line in the pick order line order.

[0083] As mentioned above, the filling of each container 264 for the ordered items is virtually planned by the controller in the manner described above. An exemplary containerization of products ordered by customers A and B is illustrated in FIG. 12. Here, both customers A and B order products A, B, C, and D. The above-mentioned containerization process described above with respect to FIGS. 11A-11C is implemented by the controller 120. Also referring to FIG. 10, an exemplary result of the containerization is illustrated in FIG. 12, where customer A specifies the following containerization rules for the product category order and customer B specifies the containerization rules for the mixed department when the best fit algorithm is employed. Here, the containerization process provides containers 264A1, 264A2 into which the items ordered by customer A are placed (container 264A1 contains items A, B, and container 264A2 contains items C, D). The containerization process also provides containers 264B1, 264B2 into which the items ordered by customer B are placed (container 264B1 contains items A, C, and container 264B2 contains items B, D).

[0084] When the containers 264 (or, overall, unbroken warehouse packs WHPK) of customer orders 299 in the consolidated order 299 are virtually planned (i.e., containerization planned), the controller 120 is configured to determine a sequencing (e.g., order of transport) of products from the product groups PG stored in the storage levels 130L assigned to the transport channels 260A-260n to enable the filling of the customer orders 299. With reference to FIGS. 13 and 14A-14B, the sequencing may assign a particular order 299 to a case unit CU of products from the storage array 130SA at least to the break pack station 140 to fulfill the containerization plan and maintain the integrity of the break pack goods BPG (e.g., the break pack goods BPG remain intact and usable after containerization, and the integrity of the products after containerization may be promoted, for example, by containerizing the products such that corrosive materials are placed below non-corrosive materials and / or the least fragile products are placed at the bottom of the container). In the sequencing process, a customer order 299 / consolidated order 299C is received, and the order 299, 299C specifies the product(s) to be utilized to replenish the customer store (or fill a direct-to-consumer e-commerce order). The controller 120 determines (e.g., with appropriate software that may be included in one or more of the warehouse management software and order management software) a plan for placing the products in containers (e.g., the containerization plan described above) and an order for conveying the products to the break-pack station 140 (i.e., an order as described herein) based on the order 299, 299C. In the example illustrated in FIGS. 14A-14B, the consolidated order 299C is split into three segments 299CS (in a manner similar to that described herein), where containerization and sequencing is performed by the controller 120 for each of the order segments 299CS.Based on the containerization and sequencing of the products, the controller 120 outputs (via suitable display at the break-pack station to a human break-pack operator or control commands to a robotic break-pack operator) a plan for pick execution to transfer the break-pack products BPG from the warehouse packs WHPK provided to the break-pack station 140 to the break-pack product containers 264 for output from the storage structure 130 (e.g., by the respective asynchronous transport systems 255A-255n and the lifts 150A-150n of the respective transport channels 260A-260n) at the output station 160UT. In the example illustrated in Figures 14A-14B, the consolidated order 299C is divided into three order segments 299CS, but it is noted that in other embodiments, the consolidated order 299C may be divided into more or less than three order segments 299CS. It is also noted that while the consolidated order is fulfilled by three orthogonal transport channels 260A-260C, in other embodiments, the transport channels filling the consolidated order 299C may be more or less than three. Additionally, although each transport channel 260A-260C is illustrated as having three storage levels 130L1-130L3, 130L4-130L6, 160L7-130L9, respectively (each associated with a respective level of a respective break pack station 140), in other embodiments the transport channels may have more or less than three storage levels.

[0085] An exemplary sequencing process is described with reference also to Figures 15A-15E. In the sequencing process, the controller 120 examines and bases the sequencing on one or more predefined characteristics of the product BPG and hardware components being sequenced. The predefined characteristics of the product BPG being sequenced include, but are not limited to, the type of package, the type of handling, and the strength of the top of the package (e.g., the characteristics include consideration of the location of the corrosive product relative to the location of the non-corrosive product in the container and the fragility of the product). Sequencing based on the hardware components enables one or more of reducing the number of residual warehouse packs (e.g., warehouse packs / case units that have not been completely emptied at the break pack station 140), utilizing the dual task functionality of the container bot 110, reducing congestion of the goods bot 262 in the break pack module 266, and optimizing utilization of the put wall 263W. Utilization of the dual task functionality of the container bot 110 includes transporting break-pack goods BPG (in a warehouse pack WHPK) to a break-pack station 140 and, on the same bot 110 trip, transporting completed / filled break-pack containers for output from the storage structure 130 or returning remaining case units CU to the storage structure 130.

[0086] To effect the sequencing of the products BPG, the controller 120 reads from any suitable memory (e.g., the controller's memory) a predetermined percentage PERTOTE (which may be configurable / reconfigurable) of break pack containers or totes 264 that are designated as reserve totes 264RSV (see FIG. 14B) (FIG. 15A, block 1502). The reserve totes 264RSV are utilized to receive overflow from other break pack containers 264 (e.g., when other break pack containers become full when no product is placed in the reserve totes) or to receive product for any other reason. The controller 120 retrieves (e.g., from a suitable memory) a maximum number MAX 264 of break pack containers that can operate in each transport channel 260A-260n (FIG. 15A, block 1503). The controller determines a maximum number MAXFILLCNT of break pack containers 264 that can be filled simultaneously for a given transport channel 260A-260n (FIG. 15A, block 1504): MAXFILLCNT=MAX264×PERTOTE [Formula 5]

[0087] The controller 120 processes the ordering for each of the product group sets or work groups PGSA-PGSn assigned to the order in parallel (as described herein) with each other as provided below with respect to blocks 1506-1525 (FIG. 15B, block 1505). The parallel processing of the product group sets PGSA-PGSn includes dynamically determining the number of customer orders to be processed in parallel, determined by, for example, one or more of the customers included in the consolidated order 299C, the customer gate time, and the number of available break pack containers at the put wall 263W (see block 1504). For example, the controller 120 sorts the products to be containerized by commodity category in ascending order, and then by warehouse pack WHPK volume and warehouse pack WHPK weight in descending order (FIG. 15B, block 1506). The controller loops through all unordered products in order 299C (FIG. 15B, block 1507) and determines if there are any unordered products in order 299C (FIG. 15B, block 1508). If all products in order 299C are ordered, the ordering process ends (FIG. 15B, block 1516).

[0088] If there are any unordered products remaining (FIG. 15B, block 1508), the controller 120 iteratively lists the product BPGs (determined from the containerization process) and their respective break pack containers 264 to be ordered (FIG. 15C, block 1509). The controller determines whether the ordered product BPGs (determined from the containerization process) require the opening of a new break pack container (FIG. 15C, block 1510). If a new break pack container is not required, for each containerization, the controller 120 adds the product BPG and its assigned break pack container 264 to the list of articles, adds the container to be ordered to the list of articles (FIG. 15C, block 1511), and returns to block 1508 to process the next product BPG.

[0089] If a new break pack container 264 is needed (FIG. 15C, block 1510), the controller 120 determines whether the number of open break pack containers NOBC (e.g., break pack containers with ordered / sequenced products) plus the number of new break pack containers NBCO opened by the currently sequenced break pack products BPG is less than or equal to the maximum number of break pack containers 264 that can be filled simultaneously, MAXFILLCNT (FIG. 15C, block 1512). NOBC+NBCO<=MAXFILLCNT [Formula 6]

[0090] If equation 6 is satisfied, the controller 120 adds the product BPG and its assigned break pack container 264 to the list of items, adds the container to be ordered to the list of items (FIG. 15C, block 1511), and returns to block 1508 to process the next product BPG.

[0091] If Equation 6 is not satisfied, the controller 120 determines whether the currently processed break pack product BPG requires any of the open break pack containers 264 (FIG. 15C, block 1513). If the currently processed break pack product BPG requires one of the open break pack containers 264 (FIG. 15C, block 1513), the controller 120 determines the number of break pack containers 264 for the current break pack product BPG that can be added to the list of break pack product BPGs without exceeding the total break pack container threshold (i.e., the maximum number of break pack containers 264 that can be filled at the same time, MAXFILLCNT) and the number of break pack containers to be sequenced (FIG. 15C, block 1514). The controller 120 adds the number of totes for the currently processed break pack product BPG that does not exceed MAXFILLCNT to the list of items, adds the containers to be sequenced to the list of items (FIG. 15C, block 1511), and returns to block 1508 to process the next product BPG.

[0092] If the currently processed break pack item BPG does not require one of the open break pack containers 264 (FIG. 15C, block 1513), the controller 120 orders the items in the list of break pack items BPGs and their respective break pack containers to be ordered (FIG. 15C, block 1515), as follows in blocks 1517-1525. For example, the controller 120 lists the break pack items BPGs and their respective break pack containers 264 that remain unordered (FIG. 15D, block 1517), and loops through all of the break pack items BPGs and their respective break pack containers 264 (FIG. 15D, block 1518). The controller 120 determines whether there are any more unordered break pack items BPGs and their respective break pack containers 264 (FIG. 15D, block 1519). If no break pack products BPG and their respective break pack containers 264 remain unsequenced (FIG. 15D, block 1519), the controller 120 returns to block 1507 (FIG. 15D, block 1525).

[0093] If no break pack items BPGs and their respective break pack containers 264 remain unsequenced (FIG. 15D, block 1519), the controller 120 determines whether the number of break pack items BPGs currently being processed is greater than or equal to three (FIG. 15E, block 1520). If the number of break pack items BPGs currently being processed is less than three, the controller 120 assigns the break pack items BPGs and their respective break pack containers 264 to the next sequence number in the sequence of the articles being delivered to the break pack station 140 (FIG. 15E, block 1521). If the number of break pack items BPGs currently being processed is 3 or more, the controller 120 generates a list of break pack containers 264 (i.e., SKUs) that can be filled by the 1 / 3 threshold of the break pack item BPG (vendor pack VNPK) for that break pack item BPG (FIG. 15E, block 1523) and assigns the break pack item BPG and its partial break pack item container 264 to the next sequence number in the sequence of the items being delivered to the break pack station 140 (FIG. 15E, block 1521). The controller increments the sequence number by 1 (FIG. 15D, block 1522) and returns to block 1519 to determine whether any break pack items BPGs and their respective break pack containers 264 remain to be sequenced (FIG. 15D, block 1519).

[0094] 1A, 1B, 2, 3A, and 16, an exemplary method for fulfilling a product order for mixed product units is described in accordance with aspects of the disclosed embodiment. The method includes inputting and distributing mixed product units BPG to a storage array 130SA of a product order fulfillment system 100 (FIG. 16, block 1600). As described herein, the storage array 130SA has at least one elevated storage level 130L, and the mixed product units BPG are inputted and distributed to the storage array 130SA in cases (i.e., case units CU (also referred to herein as warehouse packs WHPK)) of common type of product units per case. The product units BPG distributed to the cases CU in the at least one elevated storage level 130L of the storage array 130SA are automatically retrieved and outputted from the storage array 130SA by an automated transport system 277 of the product order fulfillment system 100 (FIG. 16, block 1601). The output product unit is one or more mixed singulated product units in mixed packed groups and mixed cases. As described herein, the automated transport system 277 is communicatively connected to the storage array 130SA and has at least one asynchronous transport system 255A-255n for level transport and lifts 150A-150n for inter-level transport. As described herein, the at least one asynchronous transport system 255A-255n and lifts 150A-150n are configured to form two or more transport channels 260A, 260n, at least one of which is separate and distinct from another transport channel 260A-260n. Each transport channel 260A-260n is communicatively connected to at least one elevated storage level 130L and an output (such as output station 160UT), and at least one transport channel 260A-260n provides an orthogonal transport output to each of the other transport channels 260A-260n of product units BPG distributed within the storage array 130SA.

[0095] The method also includes registering a plurality of customer orders 299 for the product unit BPG using a controller 120 communicatively connected to the two or more transport channels 260A-260n, and describing each order 299 to one or more product groups PGA-PGn of the product unit BPG (FIG. 16, block 1602). Each product group PGA-PGn has unique predefined product group properties (as described herein) that characterize the product group PGA-PGn and relate the plurality of product groups PGA-PGn to each other. The controller heuristically separates the product groups PGA-PGn of the two or more orders 299C into product group sets PGSA-PGSn based on the product group properties (FIG. 16, block 1603). Each product group set PGSA-PGSn is from the plurality of product groups PGA-PGn, is orthogonal to each of the other product group sets PGSA-PGSn, and has a maximum number of fusible product groups PGA-PGn. The controller 120 is programmed with store rules (as described herein) that define the product groups PGA through PGn and the merging possibilities of the product groups PGA through PGn with respect to one another.

[0096] The controller 120 dynamically partitions the product group sets PGSA-PGSn based at least on the amount of the assigned product group set PGSA-PGSn relative to a predetermined threshold (e.g., an average vendor pack requirement of Equation 2A or Equation 2B) of product units PEG transported via at least one transport channel 260A-260n, and the amount of each of the other assigned product group sets PGSA-PGSn relative to their respective thresholds (e.g., an average vendor pack requirement of Equation 2A or Equation 2B) of each of the other transport channels 260A-260n.

[0097] The controller 120 assigns each of the separated product group sets PGSA-PGSn to at least one transport channel 260A-260n for removal and output of the product units BPG forming the product group sets PGSA-PGSn via the at least one transport channel 260A-260n to the mixed product unit BPG order container 264 ( FIG. 16 , block 1604), where the product group sets PGSA-PGSn are assigned such that a predetermined threshold (e.g., the average vendor pack requirement of Equation 2A or 2B) of product units BPG transported via the at least one transport channel 260A-260n is not exceeded.

[0098] The controller 120 dynamically assigns the product group sets PGSA-PGSn to at least one of the transport channels 260A-260n and balances the product group sets PGSA-PGSn assigned to at least one of the transport channels 260A-260n with the other product group sets PGSA-PGSn assigned to each of the other transport channels 260A-260n. The method optimizes the transport of the product units BPG by the asynchronous transport systems 255A-255n for each customer order 299 as described herein by dividing the product group sets PGSA-PGSn and / or allocating the product group sets PGSA-PGSn. The method minimizes the transport of the bots 110 of the case CU / break-pack commodity containers 264 of the product units BPG for each customer order 299 by dividing the product group sets PGSA-PGSn and / or allocating the product group sets PGSA-PGSn.

[0099] 1A, 1B, 2, 3A, and 17, an exemplary method for fulfilling a product order for a mixed product unit is provided. The method includes distributing the mixed product units BPG to a storage array 130SA using at least one asynchronous transport system 255A-255n (FIG. 17, block 1700). As described herein, the storage array 130SA has at least one lifting storage and transport level 130L, the mixed product units BPG are distributed to the storage array 130SA in cases of CU / warehouse packs WHPK of common type of product units per case, and the at least one asynchronous transport system 255A-255n provides transport to a level (e.g., each level 130L) to automatically pick and output the product units BPG distributed to the cases of CU / warehouse packs WHPK from the storage array 130SA, each of the at least one lifting storage and transport level 130L being separate and distinct from each of the other lifting storage and transport levels 130L. It is noted that, as described herein, each lifting storage and transport level 130L provides an orthogonal transport output of product units BPG distributed to the storage array 130SA relative to each of the other lifting storage and transport levels 130L.

[0100] A controller 120, communicatively connected to at least one lifting storage and transport level 130L, registers a plurality of customer orders 299 for a product unit BPG that is characterized by one or more product groups PGA-PGn of the product unit BPG (FIG. 17, block 1701). As described herein, each product group PGA-PGn has unique predefined product group characteristics that characterize the plurality of product units BPG of the product group PGA-PGn and that relate the product group PGA-PGn to each of the other product groups PGA-PGn.

[0101] The controller 120 dynamically separates the product groups PGA-PGn describing each customer order 299 into product group sets PGSA-PGSn via a heuristic solution based on unique predetermined product group characteristics (FIG. 17, block 1702). Each product group set PGSA-PGSn is from multiple product groups PGA-PGn and is orthogonal to each of the other product group sets PGSA-PGSn. The controller 120 dynamically assigns each of the separated product group sets PGSA-PGSn to at least one lifting storage and transport level 130L (FIG. 17, block 1703). The controller 120 dynamically combines (as described herein) the product units BPG of the assigned product group sets PGSA-PGSn of the at least one lifting storage and transport level 130L into a batch of mixed product units BPG for each customer order 299 corresponding to the assigned product group sets PGSA-PGSn (FIG. 17, block 1704) within a predetermined boundary (as described herein), where the other heuristic solution is based on at least one product group characteristic and a customer or default similarity rule (as described herein). The product group sets PGSA-PGSn are dynamically assigned for picking and output of the product units BPG forming the product group sets PGSA-PGSn into the order / break pack container 264 holding the batch of mixed product units, via the at least one storage and transport level 130L, where the product group sets PGSA-PGSn are dynamically assigned so as not to exceed a predetermined threshold (e.g., average vendor pack requirement of Equation 2A or Equation 2B) of product units transported via the at least one lifting storage and transport level 130L.The controller 120 dynamically divides the product group sets PGSA-PGSn based at least on the amount of the assigned product group sets PGSA-PGSn relative to a predetermined threshold (e.g., average vendor pack requirement of Equation 2A or Equation 2B) of product units PEG transported through the at least one lifting storage and transport level 130L and the amount of each of the other assigned product group sets PGSA-PGSn relative to each threshold (e.g., average vendor pack requirement of Equation 2A or Equation 2B) of each of the other lifting storage and transport levels 130L. The controller 120 dynamically allocates the product group sets PGSA-PGSn to the at least one lifting storage and transport level 130L and balances (as described herein) the product group sets PGSA-PGSn assigned to the at least one lifting storage and transport level 130L with the other product group sets PGSA-PGSn assigned to each of the other lifting storage and transport levels 130L. As described herein, by separating product group sets PGSA-PGSn and / or allocating product group sets PGSA-PGSn, transport of product units BPG by asynchronous transport systems 255A-255n for each customer order 299 is optimized. As described herein, by separating product group sets PGSA-PGSn and / or allocating product group sets PGSA-PGSn, transport of case CU / warehouse pack WHPK bots 110 of product units BPG for each customer order 299 is minimized.

[0102] In accordance with one or more aspects of the disclosed embodiment, a mixed product unit product order fulfillment system is provided, the product order fulfillment system comprising: a storage array, an automated transport system, and a controller, the storage array having at least one elevated storage level, the mixed product units being input to and distributed in cases of common type product units per case into the storage array, the automated transport system having at least one asynchronous transport system for level transport and a lift for inter-level transport, communicatively connected to the storage array for automatically retrieving and outputting the distributed product units from the storage array into cases in the at least one elevated storage level of the storage array, the output product units being one or more mixed singulated product units in mixed pack groups and mixed cases, the at least one asynchronous transport system and the lift configured to form two or more transport channels, at least one of which is separate and distinct from another transport channel, each transport channel communicatively connected to the at least one elevated storage level and output, at least one transport channel provides an orthogonal transport output of the product units distributed within the storage array with respect to each of the other transport channels; the controller is communicatively connected to the two or more transport channels, the controller registering a plurality of customer orders for product units and describing each order into one or more product groups of product units, each product group having a unique predefined product group characteristic that characterizes the product group and relates the plurality of product groups to each other; heuristically separating the product groups of the two or more orders into product group sets based on the product group characteristics, each product group set being from a plurality of product groups, being orthogonal to each of the other product group sets, and having a maximum number of fusible product groups; and assigning each of the separated product group sets to the at least one transport channel for retrieval and output of the product units forming the product group set to an order container of mixed product units via the at least one transport channel;The product group sets are configured to be assigned such that no more than a predetermined threshold of product units are transported through the at least one transport channel.

[0103] In accordance with one or more aspects of the disclosed embodiment, the controller is configured to dynamically separate the product group sets based at least on a quantity of the assigned product group set for the predetermined threshold of product units transported via the at least one transport channel and a quantity of each of the other assigned product group sets for each threshold of each of the other transport channels.

[0104] In accordance with one or more aspects of the disclosed embodiment, the controller is configured to dynamically assign the product group sets to the at least one delivery channel and balance the product group sets assigned to the at least one delivery channel with other assigned product group sets assigned to each of the other delivery channels.

[0105] In accordance with one or more aspects of the disclosed embodiment, the customer order is for mixed product units, each unit of which is stored in a storage array in a case per case common type of product unit.

[0106] In accordance with one or more aspects of the disclosed embodiment, each customer order is for at least one of said mixed product units.

[0107] In accordance with one or more aspects of the disclosed embodiment, the at least one conveying channel is independent of each of the other ones of the two or more conveying channels such that output of product units from the at least one conveying channel is orthogonal to output from each of the other conveying channels.

[0108] In accordance with one or more aspects of the disclosed embodiment, at least one of dividing product group sets and allocating product group sets optimizes the transport of product units by the asynchronous transport system for each customer order.

[0109] In accordance with one or more aspects of the disclosed embodiment the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one elevated storage level.

[0110] In accordance with one or more aspects of the disclosed embodiment, each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

[0111] In accordance with one or more aspects of the disclosed embodiments, at least one of separating product group sets and allocating product group sets minimizes bot transport of cases of product units per customer order.

[0112] In accordance with one or more aspects of the disclosed embodiment the at least one conveying channel is connected to the at least one elevated storage level separate and distinct from each of the other conveying channels.

[0113] In accordance with one or more aspects of the disclosed embodiment, the at least one transport channel is connected to one or more corresponding elevated storage levels of the at least one storage array that are different from the elevated storage levels of the storage array that are connected to each of the other transport channels and correspond thereto.

[0114] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and their blendability with respect to one another.

[0115] According to one or more aspects of the disclosed embodiment, a product order fulfillment system for mixed product units is provided, the product order fulfillment system includes a storage array and a controller, the storage array has at least one lifting storage and transport level, the mixed product units are distributed to the storage array in cases of common type of product units per case for level transporting to automatically retrieve and output the distributed product units from the storage array using at least one asynchronous transport system, each of the at least one lifting storage and transport level is separate and distinct from each of the other lifting storage and transport levels, each of the lifting storage and transport levels provides an orthogonal transport output of the product units distributed to the storage array with respect to each of the other lifting storage and transport levels, the controller is communicatively connected to the at least one lifting storage and transport level, the controller registers a plurality of customer orders for the product units characterized by one or more product groups of the product units, each product group being associated with one or more of the product groups of the product units, the product groups ... the system has a unique predefined product group characteristic characterizing a plurality of product units of each customer order and relating the product group to each of the other product groups; dynamically dividing the product group describing each customer order into product group sets via a heuristic solution based on the unique predefined product group characteristic, each product group set being from a plurality of product groups and orthogonal to each of the other product group sets, and dynamically assigning each of the divided product group sets to the at least one lifting storage and transport level; and dynamically combining product units of the assigned product group sets of the at least one lifting storage and transport level within predefined boundaries into a batch of mixed product units for each customer order corresponding to the assigned product group set via another heuristic solution, the another heuristic solution being based on at least one product group characteristic and a customer or default similarity rule.

[0116] In accordance with one or more aspects of the disclosed embodiment, each of the separated product group sets is orthogonal to each of the other product group sets and has a maximum number of fusible product groups.

[0117] In accordance with one or more aspects of the disclosed embodiments, the product group sets are dynamically assigned for retrieval and output of product units forming the product group sets through at least one storage and transport level to an order container holding the batch of mixed product units, and the product group sets are dynamically assigned such that a predetermined threshold of product units is not exceeded for transport through at least one storage and transport channel.

[0118] In accordance with one or more aspects of the disclosed embodiment, the controller is configured to dynamically separate the product group sets based at least on a quantity of the assigned product group set for a predetermined threshold of product units transported through the at least one lifting storage and transport level and a quantity of each of the other assigned product group sets for each threshold of each of the other lifting storage and transport levels.

[0119] In accordance with one or more aspects of the disclosed embodiment, the controller is configured to dynamically assign the product group sets to the at least one lifting storage and transport level and balance the product group sets assigned to the at least one lifting storage and transport level with other assigned product group sets assigned to each of the other lifting storage and transport levels.

[0120] In accordance with one or more aspects of the disclosed embodiment, the customer order is for mixed product units, each unit of which is stored in a storage array in a case per case common type of product unit.

[0121] In accordance with one or more aspects of the disclosed embodiment, each customer order is for at least one of said mixed product units.

[0122] In accordance with one or more aspects of the disclosed embodiment, at least one of dividing product group sets and allocating product group sets optimizes the transport of product units by the asynchronous transport system for each customer order.

[0123] In accordance with one or more aspects of the disclosed embodiment the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one lifting storage and transport level.

[0124] In accordance with one or more aspects of the disclosed embodiment, each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

[0125] In accordance with one or more aspects of the disclosed embodiments, at least one of separating product group sets and allocating product group sets minimizes bot transport of cases of product units per customer order.

[0126] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and their blendability with respect to one another.

[0127] In accordance with one or more aspects of the disclosed embodiment, a method is provided for fulfilling product orders for mixed product units, the method including the steps of: inputting and distributing mixed product units into a storage array of a product order fulfillment system, the storage array having at least one elevated storage level, the mixed product units being inputted into and distributed into the storage array in cases of a common type of product unit per case, and automatically retrieving and outputting the distributed product units from the storage array in cases in the at least one elevated storage level of the storage array using an automated transport system of the product order fulfillment system, the output product units being one or more mixed singulated product units in mixed pack groups and mixed cases, the automated transport system being communicatively connected to the storage array and having at least one asynchronous transport system for level transport and a lift for inter-level transport, the at least one asynchronous transport system and the lift being configured to form two or more transport channels, at least one of which is separate and distinct from another transport channel. a plurality of transport channels communicatively connected to the at least one elevated storage level and output, the at least one transport channel providing an orthogonal transport output of the product units distributed within the storage array relative to each of the other transport channels; registering a plurality of customer orders for product units using a controller communicatively connected to the two or more transport channels and describing each order in one or more product groups of product units, each product group having a unique predefined product group characteristic that characterizes the product group and relates the plurality of product groups to one another; heuristically separating the product groups of the two or more orders into product group sets using the controller based on the product group characteristics, each product group set being from a plurality of product groups, being orthogonal to each of the other product group sets, and having a maximum number of mergible product groups;and allocating each of the separated product group sets to the at least one transport channel for removal and output of mixed product units to an order container via the at least one transport channel, the product group sets being allocated such that a predetermined threshold of product units is not exceeded for transport via the at least one transport channel.

[0128] In accordance with one or more aspects of the disclosed embodiment, the controller dynamically separates the product group sets based at least on a quantity of the assigned product group set for the predetermined threshold of product units transported via the at least one transport channel and a quantity of each of the other assigned product group sets for each threshold of each of the other transport channels.

[0129] In accordance with one or more aspects of the disclosed embodiment, the controller dynamically assigns the product group sets to the at least one delivery channel and balances the product group sets assigned to the at least one delivery channel with other assigned product group sets assigned to each of the other delivery channels.

[0130] In accordance with one or more aspects of the disclosed embodiment, the customer order is for mixed product units, each unit of which is stored in a storage array in a case per case common type of product unit.

[0131] In accordance with one or more aspects of the disclosed embodiment, each customer order is for at least one of said mixed product units.

[0132] In accordance with one or more aspects of the disclosed embodiment, the at least one conveying channel is independent of each of the other channels of the two or more conveying channels such that output of product units from the at least one conveying channel is orthogonal to output from each of the other conveying channels.

[0133] In accordance with one or more aspects of the disclosed embodiment, at least one of dividing product group sets and allocating product group sets optimizes the transport of product units by the asynchronous transport system for each customer order.

[0134] In accordance with one or more aspects of the disclosed embodiment the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one elevated storage level.

[0135] In accordance with one or more aspects of the disclosed embodiment, each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

[0136] In accordance with one or more aspects of the disclosed embodiments, at least one of separating product group sets and allocating product group sets minimizes bot transport of cases of product units per customer order.

[0137] In accordance with one or more aspects of the disclosed embodiment the at least one conveying channel is connected to the at least one elevated storage level separate and distinct from each of the other conveying channels.

[0138] In accordance with one or more aspects of the disclosed embodiment, the at least one transport channel is connected to one or more corresponding elevated storage levels of the at least one storage array that are different from the elevated storage levels of the storage array that are connected to each of the other transport channels and correspond thereto.

[0139] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and their blendability with respect to one another.

[0140] According to one or more aspects of the disclosed embodiment, a method for fulfilling product orders for mixed product units is provided, the method including the steps of distributing the mixed product units to a storage array using at least one asynchronous transport system, the storage array having at least one lifting storage and transport level, the mixed product units being distributed to the storage array in cases of a common type of product unit per case, the at least one asynchronous transport system providing level transport to automatically retrieve and output the distributed product units from the storage array to the cases, each of the at least one lifting storage and transport level being separate and distinct from each of the other lifting storage and transport levels, each of the lifting storage and transport levels providing orthogonal transport output of the product units distributed to the storage array relative to each of the other lifting storage and transport levels, and registering, with a controller communicatively coupled to the at least one lifting storage and transport level, a plurality of customer orders for the product units characterized by one or more product groups of the product units, wherein each product group has a unique, predefined product group characteristic that characterizes a plurality of product units of the product group and relates the product group to each of the other product groups; dynamically dividing, using the controller, the product groups describing each customer order into product group sets via a heuristic solution based on the unique, predefined product group characteristic, each product group set being from a plurality of product groups and orthogonal to each of the other product group sets; dynamically assigning, using the controller, each of the divided product group sets to the at least one lifting and transporting level; and dynamically combining, using the controller, via another heuristic solution, product units of the assigned product group set of the at least one lifting and transporting level within predefined boundaries into a batch of mixed product units for each customer order corresponding to the assigned product group set,The alternative heuristic solution is based on at least one product group characteristic and a customer or default similarity rule.

[0141] In accordance with one or more aspects of the disclosed embodiment, each of the separated product group sets is orthogonal to each of the other product group sets and has a maximum number of fusible product groups.

[0142] In accordance with one or more aspects of the disclosed embodiments, the product group sets are dynamically assigned for retrieval and output of product units forming the product group sets through at least one storage and transport level to an order container holding the batch of mixed product units, the product group sets being dynamically assigned such that a predetermined threshold of product units is not exceeded for transport through the at least one storage and transport level.

[0143] In accordance with one or more aspects of the disclosed embodiment, the controller dynamically separates the product group sets based at least on a quantity of the assigned product group set for a predetermined threshold of product units transported through the at least one lifting storage and transport level and a quantity of each of the other assigned product group sets for each threshold of each of the other lifting storage and transport levels.

[0144] In accordance with one or more aspects of the disclosed embodiment, the controller dynamically assigns the product group sets to the at least one lifting storage and transport level and balances the product group sets assigned to the at least one lifting storage and transport level with other assigned product group sets assigned to each of the other lifting storage and transport levels.

[0145] In accordance with one or more aspects of the disclosed embodiment, the customer order is for mixed product units, each unit of which is stored in a storage array in a case per case common type of product unit.

[0146] In accordance with one or more aspects of the disclosed embodiment, each customer order is for at least one of said mixed product units.

[0147] In accordance with one or more aspects of the disclosed embodiment, at least one of dividing product group sets and allocating product group sets optimizes the transport of product units by the asynchronous transport system for each customer order.

[0148] In accordance with one or more aspects of the disclosed embodiment the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one lifting storage and transport level.

[0149] In accordance with one or more aspects of the disclosed embodiment, each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

[0150] In accordance with one or more aspects of the disclosed embodiments, at least one of separating product group sets and allocating product group sets minimizes bot transport of cases of product units per customer order.

[0151] In accordance with one or more aspects of the disclosed embodiment, the controller is programmed with store rules that define product groups and their blendability with respect to one another.

[0152] It should be understood that the foregoing description is merely illustrative of aspects of the disclosed embodiments. Various alternatives and modifications may be contemplated by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, the aspects of the disclosed embodiments are intended to embrace all such alternatives, modifications, and variations that are within the scope of any claims appended hereto. Moreover, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be used to advantage and that such combination remains within the scope of the aspects of the disclosed embodiments.

Claims

1. A mixed product unit product order fulfillment system, the product order fulfillment system comprising: a storage array; an automated transport system; and a controller; the storage array having at least one elevated storage level, the mixed product units being input to and distributed in cases of common type product units per case into the storage array; the automated transport system has at least one asynchronous transport system for level transport and a lift for inter-level transport, and is communicatively connected to the storage array for automatically retrieving and outputting from the storage array product units distributed to cases in the at least one lifted storage level of the storage array, the output product units being one or more mixed singulated product units in mixed pack groups and mixed cases; the at least one asynchronous transport system and the lift are configured to form two or more transport channels, at least one of which is separate and distinct from another transport channel, each transport channel communicatively connected to the at least one lift storage level and output, and at least one transport channel provides an orthogonal transport output relative to each of the other transport channels of the product units distributed within the storage array; The controller is communicatively connected to the two or more delivery channels, the controller comprising: registering a plurality of customer orders for the product units, each order describing one or more product groups of the product units, each product group having unique predefined product group characteristics that characterize the product group and that relate the plurality of product groups to one another; heuristically partitioning the product groups of two or more orders into product group sets based on the product group characteristics, each product group set being from a plurality of product groups, being orthogonal to each of the other product group sets, and having a maximum number of fusible product groups; assigning each of the separated product group sets to the at least one transport channel for removal and output of the product units forming the product group sets to an order container of mixed product units via the at least one transport channel, the product group sets being assigned such that a predetermined threshold of product units being transported via the at least one transport channel is not exceeded; A product order fulfillment system that is configured to:

2. 2. The product order fulfillment system of claim 1, wherein the controller is configured to dynamically partition the product group sets based at least on an amount of the assigned product group set for the predetermined threshold of product units transported through the at least one delivery channel and an amount of each of the other assigned product group sets for each threshold of each of the other delivery channels.

3. 2. The product order fulfillment system of claim 1, wherein the controller is configured to dynamically assign the product group sets to the at least one delivery channel and balance the product group sets assigned to the at least one delivery channel with other assigned product group sets assigned to each of the other delivery channels.

4. 2. The product order fulfillment system of claim 1, wherein said customer orders are for mixed product units, each unit of which is stored in a storage array in a case of a common type of product unit per case.

5. 2. The product order fulfillment system of claim 1, wherein each customer order is for at least one of said mixed product units.

6. 2. The product order fulfillment system of claim 1, wherein the at least one delivery channel is independent of each of the other ones of the two or more delivery channels such that output of product units from the at least one delivery channel is orthogonal to output from each of the other delivery channels.

7. 2. The product order fulfillment system of claim 1, wherein at least one of dividing product group sets and allocating product group sets optimizes the transport of product units by the asynchronous transport system for each customer order.

8. 2. The product order fulfillment system of claim 1, wherein the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one elevated storage level.

9. 10. The product order fulfillment system of claim 8, wherein each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

10. 10. The product order fulfillment system of claim 8, wherein at least one of dividing the product group sets and allocating the product group sets minimizes bot transports of cases of product units per customer order.

11. 2. The product order fulfillment system of claim 1, wherein said at least one transport channel is connected to said at least one elevated storage level separate and distinct from each of the other transport channels.

12. 2. The product order fulfillment system of claim 1, wherein the at least one transport channel is connected to one or more corresponding elevated storage levels of the at least one storage array that are different from the elevated storage levels of the storage array that are connected to and correspond to each of the other transport channels.

13. The product order fulfillment system of claim 1 , wherein the controller is programmed with store rules that define product groups and their blendability with respect to one another.

14. 1. A mixed product unit product order fulfillment system, the product order fulfillment system comprising: a storage array and a controller; The storage array has at least one elevated storage and transport level, and mixed product units are distributed to the storage array in cases of common type product units per case for automatic removal and output of the case-distributed product units from the storage array using at least one asynchronous transport system; each of said at least one lifting storage and transport level being separate and distinct from each of the other lifting storage and transport levels, each of said lifting storage and transport levels providing an orthogonal transport output of said product units distributed to said storage array relative to each of the other lifting storage and transport levels; The controller is communicatively connected to the at least one lift storage and transport level, the controller comprising: registering a plurality of customer orders for product units characterized by one or more product groups of the product units, each product group having unique predefined product group characteristics that characterize a plurality of product units of said product group and relate said product group to each of the other product groups; dynamically partitioning the product groups describing each customer order into product group sets via a heuristic solution based on the unique predetermined product group characteristics, each product group set being from a plurality of product groups and orthogonal to each of the other product group sets; dynamically assigning each of the separated product group sets to the at least one lifting storage and transport level; It is configured as follows: and a product order fulfillment system, wherein product units of the assigned product group set of the at least one lifting storage and transport level are dynamically combined, within a predetermined boundary, into a batch of mixed product units for each customer order corresponding to the assigned product group set via a further heuristic solution, the further heuristic solution being based on at least one product group characteristic and a customer or default similarity rule.

15. 15. The product order fulfillment system of claim 14, wherein each of the partitioned product group sets is orthogonal to each of the other product group sets and has a maximum number of fusible product groups.

16. 15. The product order fulfillment system of claim 14, wherein the product group sets are dynamically assigned for picking and output of product units forming the product group sets through at least one storage and transport level to an order container holding the batch of mixed product units, and the product group sets are dynamically assigned such that a predetermined threshold of product units transported through at least one lifting storage and transport channel is not exceeded.

17. 15. The product order fulfillment system of claim 14, wherein the controller is configured to dynamically partition the product group sets based at least on an amount of the assigned product group set for a predetermined threshold of product units transported through the at least one lifting storage and transport level and an amount of each of the other assigned product group sets for each threshold of each of the other lifting storage and transport levels.

18. 15. The product order fulfillment system of claim 14, wherein the controller is configured to dynamically assign the product group sets to the at least one lifting storage and transport level and balance the product group sets assigned to the at least one lifting storage and transport level with other assigned product group sets assigned to each of the other lifting storage and transport levels.

19. 15. The product order fulfillment system of claim 14, wherein the customer orders are for mixed product units, each unit of which is stored in a storage array in a case of a common type of product unit per case.

20. 15. The product order fulfillment system of claim 14, wherein each customer order is for at least one of said mixed product units.

21. 15. The product order fulfillment system of claim 14, wherein at least one of dividing product group sets and allocating product group sets optimizes the transport of product units by the asynchronous transport system for each customer order.

22. 15. The product order fulfillment system of claim 14, wherein the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one lifting storage and transport level.

23. 23. The product order fulfillment system of claim 22, wherein each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

24. 23. The product order fulfillment system of claim 22, wherein at least one of dividing the product group sets and allocating the product group sets minimizes bot transports of cases of product units per customer order.

25. 15. The product order fulfillment system of claim 14, wherein the controller is programmed with store rules that define product groups and their blendability with respect to one another.

26. 1. A method for fulfilling product orders for mixed product units, the method comprising: inputting and distributing mixed product units into a storage array of a product order fulfillment system, said storage array having at least one elevated storage level, said mixed product units being inputted into and distributed into said storage array in cases of a common type of product units per case; using an automated transport system of the product order fulfillment system to automatically retrieve and output from the storage array product units distributed to cases in the at least one elevated storage level of the storage array, the output product units being one or more mixed singulated product units in mixed pack groups and mixed cases, the automated transport system being communicatively connected to the storage array and having at least one asynchronous transport system for level transport and a lift for inter-level transport; the at least one asynchronous transport system and the lift are configured to form two or more transport channels, at least one of which is separate and distinct from another transport channel, each transport channel communicatively connected to the at least one elevated storage level and output, and at least one transport channel providing an orthogonal transport output relative to each of the other transport channels of the product units distributed within the storage array; registering a plurality of customer orders for product units with a controller communicatively connected to the two or more delivery channels, describing each order to one or more product groups of product units, each product group having unique predefined product group characteristics that characterize the product group and that relate the plurality of product groups to one another; using the controller to heuristically separate the product groups of two or more orders into product group sets based on the product group characteristics, each product group set being from a plurality of product groups, being orthogonal to each of the other product group sets, and having a maximum number of fusible product groups; and using the controller, allocating each of the separated product group sets to the at least one transport channel for removal and output of product units forming the product group sets via the at least one transport channel into an order container of mixed product units, the product group sets being allocated such that no more than a predetermined threshold of product units are transported via the at least one transport channel.

27. 27. The method of claim 26, wherein the controller dynamically divides the product group sets based at least on an amount of an assigned product group set for the predetermined threshold of product units transported through the at least one transport channel and an amount of each of the other assigned product group sets for each threshold of each of the other transport channels.

28. 27. The method of claim 26, wherein the controller dynamically assigns the product group sets to the at least one delivery channel and balances the product group sets assigned to the at least one delivery channel with other assigned product group sets assigned to each of the other delivery channels.

29. 27. The method of claim 26, wherein the customer order is for mixed product units, each unit of which is stored in a storage array in a case of a common type of product unit per case.

30. 27. The method of claim 26, wherein each customer order is for at least one of the mixed product units.

31. 27. The method of claim 26, wherein the at least one conveying channel is independent of each of the other channels of the two or more conveying channels such that output of product units from the at least one conveying channel is orthogonal to output from each of the other conveying channels.

32. 27. The method of claim 26, further comprising optimizing the transport of product units through the asynchronous transport system for each customer order by at least one of dividing product group sets and allocating product group sets.

33. 27. The method of claim 26, wherein the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one elevated storage level.

34. 34. The method of claim 33, wherein each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

35. 34. The method of claim 33, wherein at least one of splitting product group sets and allocating product group sets minimizes bot transports of cases of product units per customer order.

36. 27. The method of claim 26, wherein said at least one conveying channel is connected to said at least one elevated storage level separately and differently from each of the other conveying channels.

37. 27. The method of claim 26, wherein the at least one transport channel is connected to one or more corresponding elevated storage levels of the at least one storage array that are different from the elevated storage levels of the storage array that are connected to each of the other transport channels and correspond thereto.

38. 27. The method of claim 26, wherein the controller is programmed with store rules that define product groups and their blendability with one another.

39. 1. A method for fulfilling product orders for mixed product units, the method comprising: distributing the mixed product units to a storage array using at least one asynchronous transport system; the storage array having at least one elevated storage and transport level; the mixed product units are distributed to the storage array in cases of a common type of product unit per case; the at least one asynchronous transport system provides level transport for automatically retrieving and outputting case-distributed product units from the storage array; each of said at least one lifting storage and transport level being separate and distinct from each of the other lifting storage and transport levels, each of said lifting storage and transport levels providing an orthogonal transport output of said product units distributed to said storage array relative to each of the other lifting storage and transport levels; registering, with a controller communicatively connected to the at least one lifting storage and transport level, a plurality of customer orders for product units characterized by one or more product groups of product units, each product group having a unique predefined product group characteristic that characterizes a plurality of product units of the product group and relates the product group to each of the other product groups; dynamically partitioning, with the controller, the product groups describing each customer order into product group sets via a heuristic solution based on the unique predetermined product group characteristics, each product group set being from a plurality of product groups and orthogonal to each of the other product group sets; dynamically allocating, with said controller, each of said separated product group sets to said at least one lifting storage and transport level; and using the controller to dynamically combine, within a predetermined boundary, product units of the assigned product group set of the at least one lifting storage and transport level into a batch of mixed product units for each customer order corresponding to the assigned product group set via a further heuristic solution, the further heuristic solution being based on at least one product group characteristic and a customer or default similarity rule.

40. 40. The method of claim 39, wherein each of the partitioned product group sets is orthogonal to each of the other product group sets and has a maximum number of fusible product groups.

41. 40. The method of claim 39, wherein the product group sets are dynamically allocated for picking and output of product units forming the product group sets through at least one storage and transport level to an order container holding the batch of mixed product units, the product group sets being dynamically allocated such that a predetermined threshold of product units is not exceeded for transport through the at least one lift storage and transport level.

42. 40. The method of claim 39, wherein the controller dynamically divides the product group sets based at least on an amount of an assigned product group set for a predetermined threshold of product units transported through the at least one lifting storage and transport level and an amount of each of the other assigned product group sets for each threshold of each of the other lifting storage and transport levels.

43. 40. The method of claim 39, wherein the controller dynamically assigns the product group sets to the at least one lifting storage and transport level and balances the product group sets assigned to the at least one lifting storage and transport level with other assigned product group sets assigned to each of the other lifting storage and transport levels.

44. 40. The method of claim 39, wherein the customer order is for mixed product units, each unit of which is stored in a storage array in a case of a common type of product unit per case.

45. 40. The method of claim 39, wherein each customer order is for at least one of the mixed product units.

46. 40. The method of claim 39, wherein at least one of dividing product group sets and allocating product group sets optimizes the transport of product units through the asynchronous transport system for each customer order.

47. 40. The method of claim 39, wherein the at least one asynchronous transport system comprises an autonomously guided autonomous bot that asynchronously traverses the at least one lifting storage and transport level.

48. 48. The method of claim 47, wherein each autonomously guided autonomous bot is configured to transport one case of a common type of product unit.

49. 48. The method of claim 47, wherein at least one of splitting product group sets and allocating product group sets minimizes bot transports of cases of product units per customer order.

50. 40. The method of claim 39, wherein the controller is programmed with store rules that define product groups and their blendability with one another.

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