Grid Framework Structure

Abstract

1. A grid framework structure (80) for supporting one or more robotic load handling devices operable on the grid framework structure, the grid framework structure comprising: i) a support framework structure (82) comprising a plurality of prefabricated frames (86a, b) configured to be arranged in a three-dimensional grid pattern comprising a plurality of modular storage cells (96) for storing a plurality of stacks of containers, such that adjacent modular storage cells are configured to share a common prefabricated frame (126), wherein each of the plurality of prefabricated frames (86a, b) comprises a plurality of vertical members (88) in a vertical plane and braced by bracing members (90); and ii) a track system for guiding movement of the one or more robotic load handling devices on the grid framework structure, wherein the track system is configured to be mounted to the support framework structure and to support each of the plurality of modular storage cells. the track system further comprising a track support structure (82) comprising a plurality of track supports arranged in a grid pattern corresponding to the grid pattern of the track system, the track support structure being subdivided into a plurality of modular subframes (140, 142, 144) such that each of the plurality of modular subframes comprises a subgroup of two or more grid cells of the track system, the plurality of modular subframes (140, 142, 144) being configured to be interconnected by one or more slip joints at joints between adjacent modular storage cells such that adjacent modular subframes are movable relative to one another along a substantially horizontal plane via one or more of the slip joints.

Description

[Technical Field]

[0001] The present invention relates to the field of remotely operated load handling devices on trucks located on grid framework structures for handling storage containers or receptacles stacked in the grid framework structures, and more particularly to grid framework structures for supporting the remotely operated load handling devices. [Background technology]

[0002] Storage and retrieval systems 1 comprising a three-dimensional storage grid framework structure within which storage containers / receptacles / totes are stacked on top of each other are well known. PCT Publication No. WO2015 / 185628A (Ocado) describes a known storage and fulfillment or distribution system in which stacks of receptacles or containers are arranged within a grid framework structure. The receptacles or containers are accessed by remotely operable load handling devices on trucks positioned on top of the grid framework structure. A system of this type is illustrated schematically in Figures 1 to 3 of the accompanying drawings.

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

[0004] Specifically, the grid framework structure 14 comprises a plurality of vertical uprights or upright members or columns 16 that support horizontal grid members 18, 20. A first set of parallel horizontal grid members 18 is arranged perpendicular to a second set of parallel horizontal grid members 20 to form a track system or grid structure or grid 15 comprising a plurality of grid cells 17. Each grid cell in the grid framework structure has at least one grid column for storing a stack of containers. For the avoidance of doubt, the term "grid framework structure" is used to refer to a three-dimensional structure within which storage containers are stored, and the terms "track system," "grid structure," and "grid" are used interchangeably to refer to a two-dimensional structure in a substantially horizontal plane upon which load handling devices operate. The grid cells have openings to allow load handling devices to lift containers or storage receptacles through the grid cells. In a track system, the first set of parallel horizontal grid members 18 intersect with the second set of parallel horizontal grid members at nodes. The track system is supported by upright members 16 at each of the nodes or points where the grid members intersect, so that the upright members are interconnected at their top ends by the intersecting grid members. The grid members 16, 18, 20 are typically fabricated from metal and are typically welded or bolted together, or a combination of both. The storage receptacles or containers 10 are stacked between the upright members 16 of the grid framework structure 14, so that the upright members 16 prevent horizontal movement of the stack 12 of receptacles 10 and guide vertical movement of the storage receptacles 10.

[0005] The top level of the grid framework structure 14 includes rails or tracks 22 arranged in a grid pattern across the top of the stacks 12 to define a track system. Additionally, with reference to FIG. 3 , the rails 22 support a plurality of load handling devices 30. The track system includes a first set 22a of parallel rails 22 for guiding movement of the robotic load handling devices 30 in a first direction (e.g., the X direction) across the top of the grid framework structure 14, and a second set 22b of parallel rails 22 disposed perpendicular to the first set 22a for guiding movement of the load handling devices 30 in a second direction (e.g., the Y direction) perpendicular to the first direction. In this manner, the rails 22 enable movement of the robotic load handling devices 30 laterally in two dimensions within the horizontal XY plane, so that the load handling devices 30 can be moved to a position above any of the stacks 12. For purposes of defining the present invention, the terms "robotic" load handling device and load handling device are used interchangeably in this description to refer to the same device.

[0006] The tracks or rails may be separate components from the grid members (sometimes referred to as "track supports"), or alternatively, the tracks may be unitarily integrated into, i.e., form part of, the grid members. For example, each of the first and second sets 18, 20 of horizontal grid members of a track system may function as a track support structure, and the first and second sets of tracks of the track system may be mounted to the track support structures to guide load handling devices in two dimensions on the track system.

[0007] A known load handling device, also known as a bot 30, shown in Figures 4 and 5, is described in PCT Patent Publication No. WO2015 / 019055 (Ocado), which is incorporated herein by reference, and which comprises a car body 32, where each load handling device 30 covers only a single grid space or grid cell of a grid framework structure 14. Here, the load handling device 30 comprises a wheel assembly comprising a first set of wheels 34 consisting of a pair of wheels on the front of the car body 32 and a pair of wheels 34 on the rear of the car body 32 for engaging a first set of rails or tracks to guide movement of the device in a first direction, and a second set of wheels 36 consisting of a pair of wheels 36 on either side of the car body 32 for engaging a second set of rails or tracks to guide movement of the device in a second direction. Each of the sets of wheels is driven to enable movement of the vehicle in the X and Y directions along the rails, respectively. One or both sets of wheels can be moved vertically to lift each set of wheels off its respective rail, thereby allowing the vehicle to move in a desired direction on the track system, e.g., in the X or Y direction.

[0008] The load handling device 30 is equipped with a lifting device or crane mechanism for lifting storage containers from above. The crane mechanism includes a winch tether or cable 38 wound on a spool or reel (not shown) and a grabber device 39 in the form of a lifting frame. The lifting device extends vertically and includes sets of lifting tethers 38 (one tether near each of the four corners of the grabber device) connected near or to the four corners of the lifting frame 39, also known as grabber devices, for releasable connection to the storage container 10. The grabber device 39 is configured to releasably grasp the top of the storage container 10 to lift the storage container 10 from a stack of containers in a storage system of the type shown in FIGS. 1 and 2 .

[0009] The wheels 34, 36 are arranged around the periphery of a cavity or recess known as a container-receiving recess or container-receiving space 40 at the bottom. The recess is sized to accommodate the container 10 when it is lifted by a crane mechanism, as shown in FIGS. 5(a) and 5(b). When in the recess, the container is lifted away from the rails underneath, allowing the vehicle to move laterally to a different location. Upon reaching a target location, such as another stack, an access point in a storage system, or a conveyor belt, the receptacle or container can be lowered from the container-receiving portion and released from the grabber device. The container-receiving space may comprise a cavity or recess located within the vehicle body, for example, as described in WO 2015 / 019055 (Ocado Innovation Limited). Alternatively, the body of the load handling device may comprise a cantilever, as taught in WO 2019 / 238702 (Autostore Technology AS), in which case the container-receiving space is located below the cantilever of the load handling device. In this case, the grabber device is lifted by the cantilever so that it can engage a container and lift it from the stack into the container-receiving space below the cantilever.

[0010] To ensure the stability of the grid framework structure, prior art storage systems rely heavily on various supports and braces located within or at least partially along the periphery of the grid framework structure. However, using various supports and braces (anti-shift braces) to stabilize the grid framework structure from internal and external forces is disadvantageous for several reasons. The grid framework structure occupies space or area that could be utilized for storing containers, thereby preventing optimal use of the space or area available for storing containers. Because any secondary grid support structure often requires connection to surrounding structures, such as the interior walls of a building, the need for support structures can limit the options available for positioning the grid framework structure. Requiring support structures to stabilize the grid framework structure is generally cost-ineffective and occupies useful storage space.

[0011] WO2019 / 101367 (Autostore Technology AS) teaches a freestanding storage grid that eliminates the need for a large auxiliary grid support structure by integrating the grid support structure into the storage grid structure. The grid support structure is composed of four storage columns interconnected by a plurality of vertically inclined support struts. The profile of the storage column has a cross section with a hollow central section and four corner sections, each with two vertical container guide plates for accommodating the corners of a storage container. The support struts have a width that allows them to fit between two parallel guide plates so as not to impair the storage column's ability to accommodate a container or stack of storage containers.

[0012] To erect a grid framework structure in the art, multiple vertical uprights are individually positioned one at a time on the ground in a grid-like pattern. Assembling individual vertical uprights together one at a time is sometimes referred to as "stick-built" construction. The "stick-built" method of assembling a grid framework structure requires numerous time-consuming adjustments to be made for reliable operation of a robotic load handling device on a truck. The height of the vertical uprights, and hence the level of the grid installed thereon, is adjusted by one or more adjustable feet at the base or lower end of each of the vertical uprights. Subgroups of vertical uprights are braced together to provide structural stability to the grid framework structure. The vertical uprights are interconnected at their top ends by grid members such that the grid members adopt the same grid pattern as the vertical uprights; i.e., the vertical uprights support the grid members at the points or nodes where each of the grid members intersect in the grid pattern. For purposes of describing the present invention, the points or junctions where grid members intersect or interconnect constitute the nodes of the track system and correspond to the areas where the track system is supported by vertical uprights. The resulting grid framework structure can be thought of as a free-standing linear collection of upright columns supporting a grid formed from intersecting horizontal grid members, i.e., a four-walled framework.

[0013] The arrangement of vertical uprights provides multiple vertical storage columns for storing one or more containers in a stack. The vertical uprights serve to guide a grabber device of a lifting mechanism as it engages a container in the grid framework structure and lifts it toward a load handling device operable on the grid. The size of the grid framework structure, and therefore its ability to store containers containing different items or stock keeping units (SKUs), is highly dependent on the number of vertical uprights across a given footprint of the grid framework structure. However, one of the largest bottlenecks in building a fulfillment or distribution center is erecting the grid framework structure. The time and cost to assemble the grid framework structure account for a large portion of the time and cost to build a fulfillment or distribution center. The largest and most time-consuming task involves individually erecting the vertical uprights and securing the track system to the vertical uprights.

[0014] WO2019 / 157197 (Alert Innovation Inc.) attempts to address this problem by providing an automated fulfillment system comprising a plurality of storage modules, each storage module comprising a pair of shelving modules with a number of defined storage locations for storing containers, also known as totes. The pair of shelving modules are spaced apart from one another to allow a mobile robot to pass between the pair of shelving modules to retrieve or deliver inventory from or to the storage locations. However, the automated storage system taught in WO2019 / 157197 (Alert Innovation Inc.) does not provide a high-density storage system as taught in WO2015 / 185628A (Ocado) because the shelving modules take up valuable storage space.

[0015] WO2020 / 074242 (Autostore Tech) teaches a plurality of mobile containers, each having an automated storage and retrieval system with a grid framework structure for storing storage containers (which may contain items). One of the mobile containers may be a so-called master container, having storage columns and dedicated columns for receiving storage containers from and delivering them to access stations. The remaining mobile containers may be so-called supply containers, having an automated storage and retrieval system without dedicated columns for receiving storage containers from and delivering them to access stations. Within the system, the master container may be connected to at least one supply container, so that a container handling vehicle can move from the storage grid structure of the master container to the storage grid structure of the supply container. The master container and / or supply container may be connected to multiple supply containers, which may again be connected to multiple supply containers, and so on. A pivotable intermediate element is used to connect the respective rail systems of adjacent mobile container automated storage and retrieval systems.

[0016] Therefore, there is a need for a grid framework structure that allows the grid framework structure to be erected more quickly and / or less expensively than current grid framework structures in the art. Moreover, the grid framework structure should also maximize the space or area available for storing multiple containers. Summary of the Invention

[0017] The present applicant has alleviated the above-mentioned problems by forming a grid framework structure from fewer structural components than currently practiced, as described above, while still maintaining the same structural integrity as existing grid framework structures to support the weight of one or more robotic load handling devices (which can weigh as much as 150 kg) operable on the grid framework structure. The present invention provides a grid framework structure assembled from a plurality of modular storage units, each of which provides storage for a plurality of stacks of storage containers. WO 2020 / 074242 (Autostore Tech) provides a mobile storage system in which a plurality of automated storage and retrieval systems in mobile containers can be connected together in a parallel relationship to increase the storage capacity of the mobile storage system, but no provision is made to account for the effects of thermal expansion of the grid framework structure in one or more of the mobile storage units when assembled together, resulting in movement and / or distortion of the rail system. Increasing the storage capacity of an automated storage and retrieval system by expanding the grid framework structure through the assembly of multiple modular storage units runs the risk that thermal expansion of the grid framework structure within one of the mobile storage units may generate sufficient forces to have a knock-on effect on the grid framework structure of an adjacent modular storage unit. For example, forces generated as a result of thermal expansion within the grid framework structure of a mobile storage unit may be transmitted to the adjacent mobile storage unit. The cumulative effect of such forces across multiple modular storage units may cause different areas of the grid framework structure to buckle, or at least distort. At a granular level, thermal expansion of one or more tracks may also distort one or more vertical members interconnected at their upper ends by the tracks.Because the vertical uprights are arranged to provide storage columns in the grid framework structure, distortion of one or more of the vertical uprights may cause the grabber devices and / or storage containers to jam in the vertical uprights as they are guided vertically by the vertical uprights. The terms vertical member and vertical upright are used interchangeably in this description to refer to the same feature.

[0018] WO2020 / 074242 (Autostore Tech) attempts to provide a grid framework structure that can be easily transported and erected at remote locations, however the grid framework structure in each of the mobile containers still suffers from the problem that the grid framework needs to be assembled by the "stick build" method discussed above, and therefore suffers from problems associated with long construction times and material costs.

[0019] In contrast to the "stick-built" approach to assembling a grid framework structure, which requires numerous, time-consuming adjustments to be made to the level of the rail or track system for reliable operation of the track-mounted robotic load handling device, a grid framework structure according to the present invention is erected from a plurality of prefabricated panels or frames, each of which is assembled from a subgroup of vertical members braced together by one or more bracing members. For definition purposes, the term "prefabricated" in the context of grid framework structure construction is interpreted to encompass pre-assembling or manufacturing sections of the grid framework structure prior to assembling the grid framework structure on-site, such that the grid framework structure can be assembled at a location different from the manufacture of the prefabricated sections of the grid framework structure, each prefabricated section comprising a plurality of parts or components of the grid framework structure. The different locations can be remote from the location where the grid framework structure is assembled, i.e., in a different building, or alternatively, can be assembled at the same location but in different areas of the same location, e.g., different areas of the same building. In the context of the term "panel", a prefabricated panel is formed from bracing together a subgroup of vertical members in a single plane, e.g., a single vertical plane. Preferably, the bracing members are horizontal bracing members.

[0020] The prefabricated panels or frames are assembled together in a three-dimensional grid pattern to form a plurality of modular storage cells, each sized to store multiple stacks of storage containers, i.e., each modular storage cell employs open storage space for storing multiple stacks of storage containers. The prefabricated modular panels are load-bearing in the sense that, when assembled together to form a supporting framework structure, they provide a load-bearing structure for supporting one or more load handling devices traveling on a track system mounted to the supporting framework structure. Having each of the prefabricated modular panels extend within a single plane also facilitates the ability to flat-pack the supporting framework structure for transportation. Prefabrication of the modular panels allows for rapid assembly of the supporting framework structure on-site or within a building. This has the advantage that the supporting framework structure can be constructed within an existing vacant building or warehouse.

[0021] To mitigate the effects of thermal expansion of the prefabricated frames in a single modular storage cell affecting adjacent modular storage cells in the grid framework structure, the prefabricated frames in each modular storage cell in the grid framework structure can function as stand-alone modular units spaced far enough apart to avoid affecting adjacent modular storage cells in the assembly. This prevents forces resulting from the effects of thermal expansion in a single modular storage cell from affecting the shape of adjacent modular storage cells. Because each individual modular storage cell is assembled from multiple prefabricated panels, the spacing between adjacent modular storage cells is such that the prefabricated panel components can elastically deform within the spacing but do not undergo plastic deformation beyond the spacing. One of the primary consequences of the effects of thermal expansion of the grid framework structure is distortion of the tracks on which the robotic load handling device travels. This distortion would prevent the robotic load handling device from properly moving on the grid framework structure because the wheels of the load handling device are constrained within the tracks of the track system.

[0022] To accommodate the effects of thermal expansion of an assembly of modular storage cells, the present invention provides a grid framework structure for supporting one or more robotic load handling devices operable on the grid framework structure, the grid framework structure comprising: i) a supporting framework structure comprising a plurality of prefabricated frames arranged in a three-dimensional grid pattern comprising a plurality of modular storage cells for storing a plurality of stacks of containers such that adjacent modular storage cells share a common prefabricated frame, wherein each of the plurality of prefabricated frames comprises a plurality of vertical members lying in a vertical plane and braced together by bracing members; ii) a track system for guiding movement of one or more robotic load handling devices on a grid framework structure, wherein the track system comprises a plurality of tracks mounted to the supporting framework structure and arranged in a grid pattern comprising a plurality of grid cells extending across a plurality of modular storage cells, such that each of the plurality of modular storage cells is configured to support a subgroup of two or more grid cells of the track system; the track system further comprising a track support structure comprising a plurality of track supports arranged in a grid pattern corresponding to the grid pattern of the track system, the plurality of track supports being interconnected at intersections of the plurality of track supports in the grid pattern, the track support structure being subdivided into a plurality of modular sub-frames, each of the plurality of modular sub-frames comprising a subgroup of two or more grid cells of the track system; The interconnection of the plurality of track supports at the joints between adjacent modular storage cells provides a grid framework structure with one or more slip joints such that adjacent modular subframes are movable relative to one another along a substantially horizontal plane via the one or more slip joints.

[0023] For purposes of definition, arranging tracks and track supports in a grid pattern includes having a first set of parallel tracks and / or track supports extending in a first direction and a second set of parallel tracks and / or track supports extending in a second direction, the second direction being substantially perpendicular to the first direction. Compared to the interconnections of multiple track supports at joints between adjacent storage cells, the interconnections at the intersections of multiple track supports within a given modular subframe are rigidly connected together. For purposes of defining this invention, the term "rigidly" is interpreted to mean that there is little or no movement of more than 0.5 mm relative to one another at the intersections of multiple track supports. Compared to stick-build processes for erecting grid framework structures known in the art, the grid framework structure according to the present invention is formed from multiple prefabricated panels arranged in a grid pattern such that adjacent modular storage cells share a common prefabricated frame. A common prefabricated frame shared between adjacent modular storage cells allows a track system to extend across multiple modular storage cells for one or more robotic load handling devices operable on the grid framework structure to move across the multiple modular storage cells. A plurality of prefabricated frames arranged in a three-dimensional grid pattern define a support framework structure for supporting the track system. In addition to the need to assemble the prefabricated frames forming the support framework structure more quickly than traditional stick-built methods, there is also a need to assemble the track system more quickly. Traditionally, track systems are formed by laying individual track elements in both the X and Y Cartesian directions in a horizontal plane and interconnecting the track elements to upright members where they intersect in the track system by cap plates (see PCT / EP2021 / 055217 in the name of Ocado Innovation Limited and WO18146304 in the name of Autostore Tech AS).Separately laying the individual track elements is not only time consuming but also tedious, as the track elements must be individually interconnected to the vertical uprights.

[0024] The track system includes a track support structure including a plurality of track supports arranged in a grid pattern corresponding to the grid pattern of the plurality of tracks. The plurality of track supports are interconnected at intersections of the plurality of track supports in the grid pattern. To provide a track system that can be installed more quickly than conventional methods of laying individual track elements, the track support structure is subdivided into a plurality of individual modular subframes. Each of the plurality of modular subframes includes a subgroup of two or more grid cells of the track system, e.g., a subgroup of X x Y grid cells of the track system, where X and Y can be any number greater than or equal to two. The interconnections at the intersections of the plurality of track supports within a given modular subframe are fixedly connected together. Thus, instead of building the track system from individual track elements, the track system is assembled from modular subframes. Because each modular subframe includes a subgroup of two or more grid cells of the track system, it is much easier to assemble the modular subframes together to form the track system. Each modular subframe can be sized to occupy a single modular storage cell of the supporting framework structure, such that each of the multiple modular storage cells is configured to support two or more grid cells of the track system. This provides the advantage of prefabricating sections of the track system prior to assembly onto the supporting framework structure. For example, subdividing the track support structure into multiple individual modular subframes allows sections of the track system to be hoisted onto the supporting framework structure. Multiple tracks can be integrated into the track support structure, in which case both the tracks and the track supports can be simply installed onto the supporting framework structure in a single operation. Alternatively, multiple tracks can be installed separately onto the track support structure, resulting in a dual operation involving laying the track support structure onto the supporting framework structure and then installing the tracks onto the track support structure.

[0025] In contrast to the interconnections of the track supports at intersections of the track supports, which are fixedly connected together (e.g., by bolts), the interconnections at joints between adjacent modular storage cells are movable via one or more slip or movement joints. The one or more slip or movement joints at joints between adjacent modular storage cells allow for thermal expansion in the track system, allowing adjacent modular subframes to move relative to one another along a substantially horizontal plane. The one or more slip joints at joints between adjacent modular storage cells allow for movement within a range of 0.5 mm to 10 mm, preferably 0.5 mm to 5 mm, to accommodate thermal expansion of the track supports. In other words, the one or more slip joints allow for greater movement between the track support interconnections at joints between adjacent modular storage cells than the interconnections of the track supports within a given modular subframe. Thus, movement of one modular storage cell as a result of thermal expansion does not significantly affect the movement of adjacent modular structural cells due to movement via one or more slip joints between adjacent modular storage cells. Optionally, one or more of the slip joints each comprise a bracket (e.g., a cradle bracket) configured to rest one or more track supports between adjacent modular storage cells such that adjacent modular subframes are separable. Alternatively, one or more of the slip joints can each comprise a bridge member comprising a pin and slot arrangement, whereby the pin is movable in the slot.

[0026] Considering that the truck support structure is subdivided into a plurality of modular subframes, optionally, one or more slip joints may be i) a first set of slip joints at the connections between adjacent modular storage cells in the first direction such that adjacent modular sub-frames are movable relative to one another along a substantially horizontal plane in the first direction; ii) a second set of slip joints at the connections between adjacent modular storage cells in the second direction such that adjacent modular subframes are movable relative to one another along a substantially horizontal plane in the second direction; and wherein the second direction is substantially perpendicular to the first direction.

[0027] Having first and second sets of sliding or moving joints allows adjacent modular subframes of the track support structure to move in a first direction and a second direction at the joints between adjacent modular storage cells.

[0028] To form a grid framework structure comprising a plurality of stand-alone modular storage cells or modular units, one or more vertical members of adjacent prefabricated frames are connected together by one or more fasteners at the joints between adjacent modular storage cells. To allow the connected vertical members to flex and accommodate thermal expansion of the track support structure, adjacent vertical members at the joints or joints between adjacent modular storage cells are preferably spaced apart, similar to the spacing between adjacent modular subframes. As a result of the spacing between the vertical members at the joints between adjacent modular storage cells sharing a common prefabricated frame, the distal ends of one or more of the tracks mounted to the horizontal brace members of the prefabricated frame are spaced apart. This is because the surface area of ​​the track system extending across the plurality of modular storage cells is slightly enlarged due to the spacing between the vertical members. When the vertical members are secured to the floor, bending moments resulting from thermal expansion of one or more components of the track system are transferred to the vertical members. Because the grid framework structure is formed from a plurality of prefabricated frames arranged in a grid pattern with a plurality of modular storage cells, the vertical members of adjacent modular storage cells are allowed to bend or elastically deform within the spaces between the adjacent modular storage cells without affecting the vertical members of the adjacent modular storage cells. Bending of the vertical members at the joints between adjacent modular storage cells is accommodated by movement of the modular subframes via movement along their respective slip joints. To space adjacent vertical members at the joints between adjacent modular storage cells, optionally, one or more spacers are disposed between adjacent vertical members at the joints between adjacent modular storage cells that share a common prefabricated frame.

[0029] To control deflection of the vertical members in orthogonal directions, e.g., the X and Y directions, each of the one or more spacers comprises a first spacing member or portion and a second spacing member or portion, where the first spacing member is configured to separate adjacent vertical members connected in a first direction by a first spacing, and the second spacing member is configured to separate adjacent vertical members connected in a second direction by a second spacing. At least three adjacent vertical members are connected together at joints between adjacent modular storage cells depending on the positions of the adjacent vertical members in the supporting framework structure. At the edges of the supporting framework structure, three vertical members from three separate prefabricated frames are connected in the first and second directions, i.e., two vertical members are connected to the spacer in the first direction and one vertical member is connected to the spacer in the second direction. Similarly, four adjacent vertical members within the supporting framework structure from four separate prefabricated frames are connected to the spacer in the first and second directions. Optionally, the first spacing is different from the second spacing to prevent the storage container from getting stuck on adjacent vertical members connected in the first direction and / or the second direction when being lifted through the grid cell.

[0030] To control the shape of deflection of the vertical members at the joints between adjacent modular storage cells, the one or more spacers comprise a plurality of spacers distributed along the longitudinal lengths of adjacent vertical members at the joints between adjacent modular storage cells that share a common prefabricated frame. Optionally, the spacing between the vertical members between adjacent modular storage cells that share a common prefabricated frame is in the range of 5 mm to 120 mm, preferably 10 mm to 120 mm.

[0031] To control the degree of deflection of the vertical members at the joints between adjacent modular storage cells, optionally, each of the one or more slip joints includes a limit stop for limiting relative movement between adjacent modular subframes over a predetermined distance along a substantially horizontal plane. The limit stop prevents excessive movement of the modular subframes of the track support structure at the joints between adjacent modular storage cells, which in turn prevents excessive movement or deflection of the connected adjacent vertical members in the first and second directions.

[0032] To assemble the support framework structure from a plurality of prefabricated frames that share a common prefabricated frame between adjacent modular storage cells, the plurality of prefabricated frames are arranged to form a plurality of modular units, each of the plurality of modular units having a connecting portion arranged to connect with a connecting portion of an adjacent modular unit to form a plurality of modular storage cells that share a common prefabricated frame between adjacent modular storage cells.

[0033] Preferably, the plurality of prefabricated frames are arranged to form a first type modular unit and a second type modular unit, the second type modular unit having a coupling portion configured to couple with the first type modular unit in either the first direction or the second direction to form at least a portion of a support framework structure comprising at least two modular storage cells that share at least one common prefabricated frame at a coupling between adjacent modular storage cells. To form at least two modular storage cells that share a single common prefabricated frame, optionally the first type modular unit is a closed-sided modular unit and the second type modular unit is an open-sided modular unit having an open side along one side of the modular unit, such that the open side of the second type modular unit is closed by sharing a common prefabricated frame with the first type modular unit. Optionally, the first type of modular unit comprises four prefabricated frames arranged to form a closed-sided structure, and the second type of modular unit comprises three prefabricated frames arranged to form a substantially U-shaped structure, the substantially U-shaped structure of the second type of modular unit being closed by sharing a common prefabricated frame with any one of the closed-sided structures of the first type of modular unit. Each of the plurality of modular units may be a stand-alone structure capable of moving independently relative to each other. Movement of the track system as a result of movement of one or more of the modular units in either the first direction or the second direction is mitigated by slip joints between adjacent modular units.

[0034] Optionally, the plurality of prefabricated frames are arranged to form a third type modular unit, the third type modular unit comprising at least two coupling portions configured to couple with the first, second, and / or third modular units in a first direction and a second direction, respectively, to form at least four modular storage cells.

[0035] Optionally, the third type modular unit is an open-sided modular unit along two sides of the modular unit, such that the open-sided modular unit along two sides of the modular unit is closed by sharing two common prefabricated frames with the first and / or second type modular units between adjacent modular storage cells in the first and second directions.

[0036] Optionally, the third type modular unit comprises two prefabricated frames arranged to form a substantially L-shaped structure such that the third type modular unit shares two common prefabricated frames between adjacent modular storage cells in the first direction and the second direction.

[0037] To interconnect adjacent modular subframes of the track support structure between adjacent modular storage cells by one or more slip joints, the plurality of modular subframes of the track support structure include a first type modular subframe and a second type modular subframe, the first type modular subframe being a closed-sided subframe and the second type modular subframe being an open-sided subframe, the first type modular subframe mounted to the first type modular unit and the second type modular subframe mounted to the second type modular unit, such that the open-sided subframe of the second type modular subframe is closed in a first direction or a second direction by a side of the first type modular subframe at a joint between adjacent modular subframes comprising one or more slip joints, resulting in movement between the first type modular subframe and the second type modular subframe via the one or more slip joints occurring in either the first direction or the second direction. Optionally, the plurality of modular subframes of the track support structure further comprise a third type modular subframe, the third type modular subframe being an open-sided subframe along two sides of the modular subframe, mounted to the third type modular unit, such that the open-sided subframes of the third type modular subframe along two sides of the modular subframe are closed in a first direction and a second direction by the first type modular subframe and / or the second type modular subframe between adjacent modular storage cells comprising one or more slip joints, such that movement between the third type modular subframe and the first type modular subframe and / or the second type modular subframe at the joints between adjacent moving modular storage cells occurs in the first direction and the second direction.

[0038] Conventionally, containers or storage receptacles in a stack are guided through their respective grid cells by vertical uprights at each node or intersection of the track system. The vertical uprights are typically positioned so that the track system is supported by the vertical uprights at each node or junction where the tracks cross or interconnect to form multiple storage columns for storing the storage containers one above the other in a vertical stack. As a result, as the storage container is lifted or hoisted on the track system toward a load handling device operable on the track system, all four corners of the container cooperate with the vertical uprights to prevent the container from rocking from side to side.

[0039] Assembling the prefabricated modular panels to form a three-dimensional grid framework structure creates one or more open storage spaces for accommodating multiple stacks of storage containers. The open storage spaces have a surface area that accommodates multiple grid cells of the track system. Removal of the vertical uprights means that containers are lifted and elevated in free space through the grid cells of the track system by a load handling device operable on the track system. To prevent the grabber device and any attached storage containers from swinging when lifted through the grid cells of the track system, each of the multiple modular storage cells includes multiple tote guides that extend substantially vertically between the track system and the floor, the multiple tote guides arranged in a pattern to accommodate a stack of storage containers between the multiple tote guides and guide the storage containers through their respective grid cells of the track system.

[0040] Unlike prefabricated modular panel uprights, which are mostly load-bearing, the plurality of tote guides are intended to guide grabber devices and / or storage containers through the grid cells of the track system. Preferably, each tote guide of the plurality of tote guides includes two vertical container guide plates extending between the track system and the floor for accommodating corners of the storage container. The two vertical container guide plates are configured to accommodate the corner sections of the grabber devices and / or storage containers. Thus, four tote guides would be required to accommodate the four corner sections of a standard storage container, which is generally linear in shape.

[0041] Because each of the multiple tote guides does not need to be load-bearing, lower cost manufacturing methods can be used to create the tote guides. Optionally, the multiple tote guides are formed from a sheet metal blank that is folded along parallel creases to form two substantially perpendicular container guide plates that extend longitudinally along the sheet metal blank and define the two tote guides. Examples of folding a sheet metal blank into a tote guide include, but are not limited to, cold rolling.

[0042] Although it is not necessary for the tote guides to engage or accommodate all four corners of a storage container as the container is lifted toward the track system by the lifting mechanism of the load handling device, in another embodiment of the present invention, multiple tote guides are arranged to guide one or more containers into a stack only along a pair of diagonally opposed corners of the one or more containers. This provides a level of lateral stability in the X and Y directions to the grabber device and / or storage container as the storage container is lifted along the diagonally opposed guides. By guiding the grabber device and / or its attached storage container only by the diagonally opposed tote guides, the number of tote guides required to guide the grabber device and / or its attached storage container is reduced. In practice, multiple tote guides may be arranged at alternating nodes in a first direction (e.g., the X direction) and a second direction (e.g., the Y direction) such that one or more containers are stacked between two guides only at diagonally opposed corners of the storage container, the second direction being substantially perpendicular to the first direction.

[0043] Optionally, each of the plurality of vertical members of the prefabricated frame is braced by one or more brace members. The one or more brace members extending between the plurality of vertical members of the prefabricated frame provide a lightweight, rigid framed panel comprising a triangular system of linear, interconnected structural brace elements in axial tension or compression. Preferably, the brace members of each of the plurality of prefabricated frames comprise one or more horizontal and / or diagonal brace members. There are different arrangements of the brace members to provide different triangular systems of linear, interconnected structural brace elements in axial tension or compression. Optionally, one or more brace members are arranged between the plurality of vertical members of the prefabricated braced frame in a cross-braced, K-braced, V-braced, or eccentric brace arrangement. The terms "prefabricated frame" and "prefabricated brace frame" are used interchangeably throughout this description to refer to the same feature. Optionally, each prefabricated frame comprises an A-frame. Bracing multiple vertical members with straight horizontal braces forms at least one drag strut or collector. A drag strut or collector is where at least two vertical members are braced by horizontal braces at the top or bottom of two uprights and function to collect and transfer diaphragm shear forces to the uprights. To improve the structural integrity of the support framework structure, each of the multiple vertical members in a given prefabricated frame has a cross-sectional profile that differs from the cross-sectional profiles of one or more horizontal and / or diagonal braces. For example, the structural integrity of the prefabricated frame can be increased by strengthening the diagonal braces compared to other frame members of the prefabricated frame, e.g., by increasing the wall thickness or cross-sectional profile shape of the diagonal braces. To further increase the structural integrity of the prefabricated frame, each of the one or more horizontal and / or diagonal braces can be strengthened with one or more inserts.

[0044] In addition to the track support structure being modular, the multiple tracks can also include multiple modular track sections, each of which includes substantially vertical track section elements to provide a track surface extending in a first direction and a second direction, the second direction being substantially perpendicular to the first direction. By having a track system in which each track section of the multiple track sections is formed as an integral or single body, the track sections provide a transversely extending track surface or path, e.g., a cross-shaped track surface or path. As a result, the number of track sections required to construct the track system is reduced compared to prior art track systems, thereby simplifying the layout of the track sections on the track support structure. For example, there can be a one-to-one relationship between each of the multiple track sections and a single node in the track system, in the sense that only a single track section is required at each node of the track system. A "node" in a track system is a point where multiple tracks and / or track supports intersect in a grid pattern. In prior art track systems, there is a two-to-one relationship between the number of track sections and a single node in the track system, in the sense that there is one track section extending in a first direction and a separate track section extending in a second direction. In one example of achieving a one-to-one relationship between each of the plurality of track sections and each node in the track system, preferably each track section of at least a portion of the plurality of modular track sections: a) a first track section element extending in a first direction; b) a second track section element intersecting the first track section element and extending in a second direction such that the track section is configured to be mounted to one or more nodes of a track support structure; and More preferably, each of the plurality of track sections is formed as a unitary or monolithic body. In other words, each of the plurality of track sections may be cross-shaped, having a first track section element extending in a first direction and a second track section element intersecting the first track section element and extending in a second direction. The first and second track section elements may also be referred to as crossing or branching portions of the track section. Forming the track section as a single or monolithic body allows the track section to be installed at each node of the track support structure where the track supports intersect. This eliminates the need for separate track or rail elements extending in the first and second directions, as in prior art solutions. In addition to simplifying the installation of the plurality of tracks on the track support structure, the cross-shaped configuration of the modular track sections allows the modular track sections to bridge the joints between adjacent modular storage cells, providing a continuous track surface extending across the adjacent modular storage cells.

[0045] However, the present invention is not limited to having a one-to-one relationship between a single track section and the number of nodes in a track system. For example, a single track section formed as a one-piece body may be configured to extend across multiple nodes in a track system and further provide a transversely extending track surface.

[0046] Generally in the art, to ensure that the track system is level and to compensate for uneven floors, the level of a track system mounted to a vertical upright is adjusted by having adjustable leveling feet at the base or bottom end of the vertical upright with threaded axles that can be extended or retracted relative to the base of the vertical upright. To compensate for uneven floor or ground, one or more of the prefabricated frames forming the supporting framework structure may be mounted on adjustable leveling feet with threaded axles that can be extended or retracted relative to the base of the prefabricated frame.

[0047] The present invention provides a storage and retrieval system, comprising: i) a grid framework structure according to the present invention; ii) a plurality of stacks of containers disposed in storage columns located below the track system, wherein each storage column is located vertically below a grid cell; iii) a plurality of cargo handling devices for lifting and moving the stacked containers in the stack; a plurality of load handling devices remotely operated to move laterally on a track system above the storage columns to access containers through the grid cells, each of the plurality of load handling devices comprising: a) a wheel assembly for guiding a load handling device on a track system; b) a container receiving space located above the track system; c) a lifting device arranged to lift a single container from the stack into the container receiving space; A storage and retrieval system is provided, comprising:

[0048] The present invention provides a method of assembling a grid framework structure according to the present invention, comprising the steps of: i) assembling a plurality of prefabricated frames in a grid pattern to form a supporting framework structure comprising a plurality of modular storage cells such that adjacent modular storage cells share a common prefabricated frame; ii) installing a plurality of modular subframes in a substantially vertical orientation on a supporting framework structure such that joints between adjacent modular subframes are interconnected by one or more slip joints; The method further comprises:

[0049] The number of slip joints at the joints between adjacent modular storage cells depends on the position of the modular subframe in the track support structure, which in turn depends on the number of sides of the modular subframe that abut adjacent modular subframes in the track support structure. For example, a modular subframe located in the center of the track support structure will interface with four adjacent modular subframes, with each of the four sides of the modular subframe interfacing with one of the four adjacent modular subframes. A modular subframe located at the edge of the track support structure will interface with three adjacent modular subframes, with three of the four sides of the modular subframe interfacing with the adjacent modular subframes and the fourth side of the modular subframe forming part of the edge of the track support structure. A modular subframe located at the corner of the track support structure will interface with two adjacent modular subframes, with two of the four sides of the modular subframe interfacing with the adjacent modular subframes and the other two sides of the modular subframe forming part of the edge of the track support structure. Thus, in a given modular subframe, one or more slip joints extend in orthogonal directions to accommodate movement in a first direction (x-direction) and a second direction (y-direction). To accommodate one or more slip joints on different sides of the modular subframe, each of the multiple modular subframes will need to be mounted to a supporting framework structure in a substantially vertical orientation.

[0050] Optionally, the step of assembling the supporting framework structure comprises: i) assembling four prefabricated frames to form a closed-sided modular unit defining a first type of modular unit; ii) assembling a plurality of prefabricated frames into a first type of modular unit; and wherein the plurality of prefabricated frames comprises three prefabricated frames arranged in a substantially U-shaped configuration defining a second type modular unit such that the second type modular unit shares a common prefabricated frame with the first type modular unit.

[0051] In the construction of a grid framework structure, a first type of modular unit may be defined as the origin of construction, and the remaining modular units are constructed around the origin. The origin provides a stable structure for attaching prefabricated frames to the origin (the first type of modular units). The remaining modular units may be assembled on the origin by separately assembling the prefabricated frames to the origin, or optionally, the second type of modular units may be pre-assembled prior to being assembled on the first type of modular units.

[0052] Optionally, the plurality of prefabricated frames further comprises two prefabricated frames arranged in a substantially L-shaped configuration defining a third type of modular unit such that the third type of modular unit shares a common prefabricated frame with the second type of modular unit.

[0053] Optionally, the method further comprises pre-assembling the modular units of a third type prior to assembly onto the modular units of the second type.

[0054] Further features of the present invention will become apparent from the detailed description when considered in conjunction with the drawings.

[0055] Further features and aspects of the present invention will become apparent from the following detailed description of illustrative embodiments which proceeds with reference to the drawings. [Brief explanation of the drawings]

[0056] [Figure 1]1 is a schematic diagram of a grid framework structure according to known systems; [Figure 2] 2 is a schematic diagram of a top view showing a stack of containers arranged within the support framework structure of FIG. 1. [Figure 3] 1 is a schematic diagram of a known storage system comprising a load handling device operating on a grid framework structure; FIG. [Figure 4] FIG. 1 is a schematic perspective view of a cargo handling device showing a lifting device gripping a container from above. [Figure 5] (a) A schematic perspective cutaway view of the cargo handling device of Figure 4 showing a container accommodated within the container receiving space of the cargo handling device, and (b) a schematic perspective cutaway view of the cargo handling device of Figure 4 showing the container receiving space of the cargo handling device. [Figure 6] FIG. 1 is a top view of a section of a known grid structure comprising four closely spaced grid cells, each of which constitutes a storage column, showing the intersections or nodes of the grid members supported by vertical uprights. [Figure 7] FIG. 1 is a perspective view showing four vertical uprights that make up storage spaces or columns within a grid framework structure. [Figure 8] FIG. 1 is a perspective view showing an arrangement of tracks and track supports interconnected at their nodes or intersections by cap plates. [Figure 9] FIG. 1 is a perspective view of a track support or grid member. [Figure 10] FIG. 10 is a perspective view of a cap plate for interconnecting vertical uprights to grid members at nodes. [Figure 11] FIG. 10 is a perspective cross-sectional view of the interconnection of vertical uprights to a grid by cap plates at the nodes. [Figure 12] FIG. 1 is a perspective view of a track or rail. [Figure 13a] 1 is a perspective view of a grid framework structure according to an embodiment of the present invention; FIG. [Figure 13b]FIG. 1 is a perspective view of individual prefabricated frames used to assemble the support framework structure. [Figure 13c] FIG. 13b is a perspective view of the vertical uprights used to manufacture the prefabricated frame shown in FIG. [Figure 13d] FIG. 13c is a perspective view of a diagonal brace member used to manufacture the prefabricated frame shown in FIG. [Figure 13e] FIG. 13d is a perspective view of a horizontal brace member used to manufacture the prefabricated frame shown in FIG. [Figure 14] 1A and 1B are schematic diagrams illustrating thermal expansion and contraction of adjacent prefabricated frames in a supporting framework structure, respectively; FIG. [Figure 15a] FIG. 1 is a schematic diagram illustrating thermal expansion of adjacent spaced apart prefabricated frames in a supporting framework structure. [Figure 15b] 1 is a schematic diagram illustrating thermal contraction of adjacent spaced apart prefabricated frames in a support framework structure. FIG. [Figure 15c] FIG. 1 is a perspective view of a section grid framework structure showing spacing between adjacent modular storage units according to the present invention. [Figure 15d] FIG. 1 is a perspective top view of a vertical upright from four separate prefabricated panels connected in a first direction along axis XX and in a second direction along axis YY. [Figure 15e] 10A-10C are perspective views of example spacers used to separate adjacent vertical uprights connected in a first direction and a second direction. [Figure 16] FIG. 14 is a perspective view of a supporting framework structure of the grid framework structure shown in FIG. 13. [Figure 17] 17 is a schematic diagram illustrating a top view of the support framework structure in FIG. 16 showing the arrangement of multiple interlocking modular units. [Figure 18]FIG. 1 is a perspective view of a partially assembled first type of modular unit of the supporting framework structure showing the assembly of the prefabricated frame. [Figure 19] FIG. 19 is a perspective view of the assembled first type modular unit shown in FIG. 18, representing a single modular storage cell. [Figure 20] FIG. 20 is a perspective view showing a first type modular subframe of a truck support structure being installed on the first type modular unit shown in FIG. 19. [Figure 21] FIG. 1 is a perspective view of a first type modular unit assembled with an installed first type modular subframe. [Figure 22] FIG. 1 is a perspective view of a grid framework structure comprising two modular storage cells of a supporting framework structure and a mating modular subframe of a track supporting structure. [Figure 23] FIG. 10 is a perspective view illustrating the joints between adjacent modular subframes of the track system with one or more slip or movement joints at the joints between adjacent modular storage cells. [Figure 24] 10A-10C are perspective views of individual slip or movement joints for joining adjacent modular subframes of a track support structure at the joints between adjacent modular storage cells. [Figure 24b] FIG. 10 is a perspective view of a section of a grid framework structure at a joint of modular storage cells showing the slip joints mounted to the track supports. [Figure 24c] 24b is a perspective view of a slip joint member using adjacent modular subframes connected at the joints between the modular storage cells shown in FIG. 24b according to a second example of the present invention. [Figure 24d] FIG. 24c is a perspective underside view of the intersection of track supports at the joint between adjacent modular storage cells, showing the installation for the slip joint shown in FIG. 24c. [Figure 24e]24d is a perspective underside view of the intersection of the track supports at the joint between adjacent modular storage cells shown in FIG. 24c, illustrating the slip joint shown in FIG. 24d. [Figure 25] FIG. 1 is a perspective view of a grid framework structure with three modular storage cells of a supporting framework structure. [Figure 26] FIG. 1 is a perspective view showing the assembly of a grid framework structure with four modular storage cells. [Figure 27] FIG. 27 is a perspective view showing a track support structure extending across the four modular storage cells of FIG. 26. [Figure 28] FIG. 28 is a top view of the grid framework structure shown in FIG. 27 showing adjacent first, second, and third type modular subframes at the joints between adjacent modular storage cells. [Figure 29] FIG. 10 is a perspective view illustrating multiple track sections mounted to a track support structure at the joints between adjacent modular storage cells. [Figure 30] FIG. 10 is a perspective view illustrating the assembly of track sections onto a track support structure. [Figure 31] FIG. 10 is a perspective view showing a section of the underlying track support structure at a node of the intersecting track supports. [Figure 32] FIG. 2 is a perspective view of a top view of a track section according to an embodiment of the present invention. [Figure 33] 33 is a perspective view of the underside of the track section shown in FIG. 32, showing a number of tabs for connecting to the track support structure shown in FIG. 31. FIG. [Figure 34] 1 is an illustration of an arrangement of track sections in a track system according to the present invention. [Figure 35] FIG. 1 is an isometric view of a grid framework structure showing multiple tote guides positioned to guide a storage container along diagonally opposed corners of the storage container. [Figure 36]1 is a perspective view illustrating a set of tote guides formed from a sheet metal blank folded along parallel folds. FIG. [Figure 37] FIG. 10 is a perspective view illustrating a portion of a prefabricated frame sandwiched between a set of tote guides. [Figure 38] 37 is a perspective view illustrating a plurality of tote guides shown in FIG. 36 and a cap plate for coupling with a track system. [Figure 39] 10 is a perspective view illustrating cooperation between a cap plate mounted to a plurality of tote guides and a track system. FIG. [Figure 40] FIG. 28 is a perspective view illustrating the arrangement of multiple modular safety barriers installed around the perimeter of the track system of the grid framework structure shown in FIG. 27. [Figure 41] FIG. 10 is a perspective view illustrating the placement of an outer covering around the periphery of a supporting framework structure. [Figure 42a] FIG. 1 is a perspective view of the AGV and lifting mechanism engaging with the prefabricated frame prior to lifting. [Figure 42b] FIG. 1 is a perspective view of the orientation of the prefabricated braced panels prior to assembly onto the supporting framework structure. [Figure 43a] FIG. 1 is an isometric view of a grid framework structure showing a mezzanine level incorporated into the supporting framework structure. [Figure 43b] FIG. 1 is an isometric view of a grid framework structure showing the arrangement of modular units of the supporting framework structure surrounding and spanning the mezzanine level. [Figure 43c] FIG. 1 is an isometric view of the grid framework structure showing an exploded view of the connection between the first area of ​​the grid framework structure and the mezzanine floor. [Figure 43d] FIG. 10 is an isometric view of the grid framework structure showing a second area of ​​the grid framework structure above the mezzanine level and a pick station below the mezzanine level. [Figure 44]FIG. 10 is an enlarged view of a bridge element connecting a track system between a first region of the grid framework structure and a second region of the grid framework structure. [Figure 45] FIG. 45 is a perspective view of a single bridge element shown in FIG. 44. DETAILED DESCRIPTION OF THE INVENTION

[0057] The present invention builds upon known features of storage systems such as the grid framework structures and cargo handling devices described above with reference to Figures 1-5.

[0058] Figure 6 shows a top view of a section or portion of a conventional track system 15 comprising four closely spaced grid cells 42, and Figure 7 shows a perspective side view of a single grid cell 42 supported by four vertical uprights 16 to form a single storage column 44 for storing one or more containers 10 in a stack. The grid framework structure can be thought of as being divided into a supporting framework structure comprising a plurality of vertical uprights and a track system. The track system comprises a plurality of grid members supported by the supporting framework structure and arranged in a grid pattern comprising a plurality of grid cells.

[0059] Each vertical upright 16 is generally tubular. In a cross-section of the storage column 44 in a horizontal plane shown in FIG. 2 , each vertical upright 16 comprises a hollow center section 46 (typically a box-shaped section) having one or more tote guides 48 mounted or formed at the corners of the hollow center section 46 extending along the longitudinal length of the vertical upright 16 to guide the movement of containers along the storage column 44. The one or more guides 48 comprise two vertical container guide plates configured to accommodate a corner of a container or a corner of a stack of containers. In other words, each corner of the hollow center section 46 defines two sides of a substantially triangular area that can accommodate a corner of a container or storage receptacle. These corners are evenly spaced around the hollow center section 46 so that multiple vertical uprights 16 can provide multiple adjacent storage columns, and each vertical upright 16 can be common to or shared by up to four separate storage columns. FIG. 7 also shows that each of the vertical uprights 16 is mounted on an adjustable grid leveling mechanism 19 at the foot of the vertical upright which comprises a base and a threaded shaft that can be extended or retracted to compensate for uneven floors.

[0060] The horizontal cross-section of the storage columns 44 in FIG. 2 shows that each storage column 44 is made up of four vertical uprights 16 positioned at the corners of the container or storage receptacle 10. The storage column 44 corresponds to a single grid cell. The cross-section of the vertical uprights 16 is constant along the entire length of the vertical uprights. The perimeter of the container or storage receptacle in FIG. 2 shows the container or storage receptacle having four corners and the arrangement of the four vertical uprights 16 at the corners of the container or storage receptacle within the storage column 44. The corner sections of each of the four vertical uprights, one from each of the four vertical uprights, ensure that the container or storage receptacle stored in the storage column 44 is guided into the correct position relative to any containers or storage receptacles stored within the storage column and stacks of containers or storage receptacles in the surrounding storage columns. A load handling device (not shown), operable on the track system 15, can lift the container or storage receptacle as it is guided along the vertical uprights 16 through the grid cell 42. The vertical uprights 16 have the dual purpose of (a) providing structural support for the track system 40 and (b) guiding the containers or storage vessels 10 into position through their respective grid cells 42 .

[0061] Conventionally, during the assembly of a grid framework structure, individual vertical uprights 16 are erected first. The procedure for assembling the individual vertical uprights 16 is sometimes referred to as the “stick-build” technique. The upper or top ends of the vertical uprights 16 are then interconnected by a plurality of grid members. The top view of a section of the track system 15 shown in FIG. 6 shows a series of horizontal cross beams or grid members 18, 20 arranged to form a plurality of rectangular frames that make up grid cells 42; more specifically, a first set of grid members 18 extending in a first direction X and a second set of grid members 20 extending in a second direction Y, with the second set of grid members 20 running transversely to the first set of grid members 18 in a substantially horizontal plane; i.e., the track system is represented by Cartesian coordinates in the X and Y directions. The terms “vertical upright(s),” “upright(s),” “upright(s),” and “upright column(s)” are used interchangeably in this description to mean the same thing. For purposes of describing the present invention, the points or junctions where grid members intersect or meet, indicated by the shaded squares in Figure 6, may be defined as nodes or intersections 50. From the layout of at least a portion or section of a known track system 40 making up four adjacent grid cells 42 shown in Figure 6, it is clearly apparent that each intersection or node 50 of the track system 40 is supported by a vertical upright 16. From the section or at least a portion of the track system 40 shown in Figure 6, the four adjacent grid cells are supported by nine vertical uprights 16, i.e., three sets of vertical uprights 16 that support the track system in three rows, where each row comprises three nodes 50.

[0062] Each grid member can comprise a track support 18, 20 and / or a track or rail 22a, 22b (see track system in FIG. 8 ), whereby the track or rail 22a, 22b is mounted to the track support 18, 20. A load handling device is operable to move along the track or rail 22a, 22b of the present invention. Alternatively, the track 22a, 22b can be integrally formed with the track support 18, 20 as a single unit, for example, by extrusion. At least one grid member in the set, e.g., a single grid member, can be subdivided or segmented into individual grid elements that can be joined or connected together to form the grid members 18, 20 extending in the first or second direction. When a grid member comprises a track support, the track support can also be subdivided into individual track support elements that are coupled or fixedly connected together to form the track support. Individual track support elements that make up the track support extending in the first and second axial directions are shown in FIG. 8 . The individual track support elements 56 used to construct the track supports 18, 20 are shown in Figure 9. In cross section, the track supports 18, 20 can be solid supports of C-shaped, U-shaped, or I-shaped cross section, or even double C-shaped or double U-shaped supports. In a particular embodiment of the invention, the track support elements 56 comprise double back-to-back C-sections bolted together.

[0063] A connecting plate or cap plate 58, as shown in FIG. 8 , may be used to link, join, or fixedly connect individual track support elements 56 together in both a first direction and a second direction at the junctions where multiple track support elements meet in the track system 15; i.e., the cap plate 58 is used to connect the track support elements 56 to the vertical uprights 16 together. As a result, the vertical uprights 16 are interconnected at their upper ends at the junctions where multiple track support elements meet in the track system 15 by the cap plate 58; i.e., the cap plate is located at the node 50 of the track system 15. As shown in FIG. 10 , the cap plate 58 is cross-shaped with four connection portions 60 for connecting to the ends of the track support elements or at their intersections 50 anywhere along the length of the track support elements 56. The interconnection of the track support elements to the vertical uprights at the node by the cap plate 58 is clearly shown in the cross-sectional profile of the node 50 shown in FIG. 11 . The cap plate 58 includes a spigot or protrusion 62 sized to fit within the hollow central section 46 of the vertical uprights 16 with an interference fit to interconnect the plurality of vertical uprights 16 to the track support elements, as shown in FIG. 11 . Also shown in FIG. 11 are track support elements 56 a, 56 b extending vertically in both a first direction (x-direction) and a second direction (y-direction). Connection portions 60 are perpendicular to each other for connecting to the track support elements 56 a, 56 b extending in the first and second directions, respectively. The cap plate 58 is configured to be bolted to the ends of the track support elements 56 a, 56 b or along the length of the track support elements to form a rigid connection with the cap plate 58. In accordance with the present invention, each of the track support elements 56 a, 56 b is positioned to interlock with one another at nodes to form the grid structure 40. To accomplish this, the distal or opposing end of each of the track support elements 56a, 56b includes a locking feature 64 for interconnecting with a corresponding locking feature 66 on an adjacent track support element.In certain embodiments of the invention, the opposing or distal ends of one or more track support elements include at least one hook or tongue 64 receivable into an opening or slot 66 intermediate adjacent track support elements 56 at the junctions where the track support elements cross in the track system 40. Referring again to FIG. 9 in conjunction with FIG. 11, the hooks 64 at the ends of the track support elements 56 are shown as being receivable into the openings 66 of adjacent track support elements that extend across the vertical uprights 16 at the junctions where the track support elements 56 cross. Here, the hooks 64 are provided through the openings 66 on both sides of the track support element 56b. The openings 66 are intermediate the lengths of the track support elements 56, so that, when assembled together, adjacent, parallel track support elements 56 in the first and second directions are offset by at least one grid cell. This is clearly shown in FIG. 8.

[0064] To complete the track system 40, tracks 22a, 22b are installed on the track support elements 56, with the track support elements 56 interlocking together in a grid pattern, with track supports 18 extending in a first direction and track supports 20 extending in a second direction. The tracks 22a, 22b are either snap-fit ​​and / or fitted onto the track supports 18, 20 in a slip-fit ​​configuration (see FIG. 8). Like the track supports, the tracks include a first set 22a of tracks extending in a first direction and a second set 22b of tracks extending in a second direction, the first direction being perpendicular to the second direction. The first set 22a of tracks is subdivided into a plurality of track elements 68 in a first direction such that, when assembled, adjacent parallel track elements in the first direction are offset by at least one grid cell. Similarly, the second set of tracks 22b is subdivided into multiple track elements 68 in the second direction such that, when assembled, adjacent track elements in the second direction are offset by at least one grid cell. This is clearly shown in FIG. 8. An example of a single track element 68 is shown in FIG. 12. Similar to the track support elements, multiple track elements in the first and second directions are placed together to form a track in both directions. The track elements 68 fit into the track supports 18, 20 with an inverted U-shaped cross-sectional profile shaped to rest on or overlap the tops of the track supports 18, 20. One or more protrusions extending from each branch of the U-shaped profile engage the ends of the track supports 18, 20 in a snap-fit ​​configuration. It is equally plausible that the track systems 22a, 22b could be integrated into the track supports 18, 20 rather than being separate components.

[0065] As can be appreciated from the above description, the process of assembling a grid framework structure, which involves erecting vertical uprights, connecting grid members, and installing tracks, is very time-consuming due to the multiple separate components required to assemble the grid framework structure. The process of erecting a grid framework structure can take several weeks; in worst-case scenarios, the process can take several months. As demand for e-commerce rapidly grows, particularly in the retail sector, there is an increasing demand for distribution centers, also known as customer fulfillment centers (CFCs), in more locations than just a few serving major cities to meet growing demand from customers. The increased presence of distribution centers in more locations also has the effect of reducing the time required to complete last-mile logistics for the movement of goods from distribution centers to their final destinations. Such last-mile logistics is also an important consideration for keeping goods, such as perishable foods, fresh at their final destinations. One of the major bottlenecks to establishing distribution centers in more locations is the time and cost required to erect a grid framework structure. Not only are the time and cost of erecting a grid framework structure a cause for concern when establishing a distribution center, but the grid framework structure should also have the flexibility to be assembled in several existing locations, including existing warehouses, rather than a custom-built warehouse purely to accommodate the grid framework structure.

[0066] Applicant has alleviated the above-mentioned problems by forming a grid framework structure in accordance with the present invention from fewer structural components than currently practiced as described above, while still maintaining the structural integrity of existing grid framework structures to support the weight of one or more robotic load handling devices operable thereon. In contrast to existing grid framework structures as described above, a grid framework structure in accordance with the present invention is erected from prefabricated modular structural components. The prefabricated modular structural components are load-bearing in the sense that, when assembled together to form the grid framework structure, the prefabricated modular structural components provide a three-dimensional load-bearing structure to support one or more load handling devices traveling on a track system. The use of prefabricated modular structural components to erect a grid framework structure in accordance with the present invention allows the grid framework structure to be assembled much more quickly than a conventional "stick-build" approach in which individual vertical uprights are first erected one by one on the floor, and then track supports are installed on top of the vertical uprights.

[0067] FIG. 13 a illustrates a grid framework structure 80 assembled from prefabricated modular structural components in accordance with the present invention. The grid framework structure 80 may be divided into a support framework structure 82 and a track system 84 for guiding the movement of one or more robotic load handling devices 30 on the support framework structure 82. When assembling the grid framework structure 80, the support framework structure 82 is assembled first, and then the track system 84 is installed on the support framework structure 82. The track system 84 is elevated above ground level by the support framework structure 82 to create an open storage space for storing multiple stacks of storage containers. Either the support framework structure 82 or the track system 84, or both the support framework structure 82 and the track system 84, may be assembled from modular structural components. In the particular embodiment illustrated in FIG. 13 a, both the support framework structure 82 and the track system 84 are assembled from prefabricated modular structural components to form the three-dimensional grid framework structure 80.

[0068] In a particular example of the present invention, the support framework structure 82 is formed from a plurality of prefabricated frames or panels 86 a,b arranged in a grid pattern to define a three-dimensional support framework structure. Prefabrication of the frames 86 a,b involves assembling and fastening the separate components of the support framework structure 82 together prior to erecting the support framework structure 82 such that each component of the prefabricated frames 86 a,b lies in a common plane. In other words, the prefabricated frames 86 a,b can be assumed to be planar. This allows for easier assembly of the support framework structure 82 because the use of prefabricated frames 86 a,b significantly reduces the time and effort required to assemble the support framework structure 82, rather than erecting multiple vertical uprights one-by-one in a "stick-by-stick" manner and then installing a grid structure onto the support framework structure, as is currently done in the art.

[0069] Prefabricated frames 86 a, b forming a support framework structure according to a specific embodiment of the present invention shown in FIG. 13 b are each configured as a prefabricated braced frame or panel 86 a, b comprising a plurality of uprights or vertical members 88 braced together by one or more brace members 90, 92 extending between the uprights 88. In the specific embodiment of the present invention shown in FIG. 13 b, the one or more brace members 90, 92 comprise horizontal brace members 90 and diagonal brace members 92. The braces allow subgroups of uprights 88 to be assembled together prior to assembly into the support framework structure 82. To allow the prefabricated braced frames 86 a, b to be flat-packed for ease of transportation, the uprights 88 of each of the prefabricated braced frames 86 a, b extend in a common plane and are secured together by one or more brace members 90, 92. One or more brace members connecting the uprights are in the same plane as the uprights, so each prefabricated brace frame is planar. Each upright 88 of the uprights may be an I-, H-, or U-shaped solid support beam with C- or L-shaped opposing beam flanges to allow the uprights to be braced together by one or more brace members. The cross-sectional profiles of each of the vertical members 88, horizontal brace members 90, and diagonal brace members 92 in a given prefabricated frame 86 a, b may be the same or different. In certain embodiments of the present invention, the cross-sectional profiles of each of the vertical members 88, horizontal brace members 90, and diagonal brace members 92 in a given prefabricated frame 86 a, b are different. Differences in the cross-sectional profiles of each of the vertical members 88, horizontal brace members 90, and diagonal brace members 92 in a given prefabricated frame 86 a, b serve to tailor the physical properties of the supporting framework structure. For example, the supporting framework structure should have sufficient ultimate tensile strength (UTS) to prevent fracture or failure under tension, yet be flexible enough to allow the supporting framework structure to bend or flex as a result of thermal expansion.By prefabricating the prefabricated frames from different shaped cross-sectional profiles of the vertical members 88, horizontal braces 90, and diagonal braces 92, the physical properties of the prefabricated frames 86a, b can be tailored to the required physical properties.

[0070] Figures 13(c-e) show different cross-sectional profiles of the vertical members, horizontal braces, and diagonal braces used to manufacture prefabricated frames 86a, b according to the present invention. Figure 13d shows a diagonal brace member 92 having a box-shaped cross-sectional profile, and Figure 13e shows a horizontal brace member having a C-shaped cross-sectional profile. The cross-sections of the vertical uprights are shaped to provide elastic or flexible portions and connection portions for connecting to the horizontal brace members. Figure 13c also shows openings 89 for connecting the vertical members of adjacent prefabricated frames together in a supporting framework structure. However, to reduce the cost and improve the structural integrity of the prefabricated brace frame without compromising its lightweight nature, each load-bearing member of the prefabricated brace frame can have a single cross-sectional profile. For example, the load-bearing members include uprights 88 and diagonal bracing members 90, 92, i.e., the entire prefabricated diagonal bracing frame is formed from the same type of load-bearing members having a C-shaped cross section. To reduce the cost of manufacturing the grid framework structure, each of the uprights 88 and / or diagonal bracing members 90, 92 may be formed from a folded sheet metal blank having one or more creases. Examples of folding a sheet metal blank to form the uprights 88 include, but are not limited to, cold rolling.

[0071] Each of the plurality of uprights 88 of the prefabricated braced frame 88 comprising the supporting framework structure 82 is braced by both horizontal bracing members 90 and diagonal bracing members 92. In the particular example shown in FIG. 13b, the plurality of horizontal bracing members 90 extend between the upper and middle regions of the plurality of uprights 88. The horizontal bracing members 90a, b function as load-bearing beams extending between the uprights 88, particularly those installed at their upper ends. The horizontal bracing members 90 include, but are not limited to, load-bearing beams having cross-sectional shapes such as L (angle), C (channel), or tube. The horizontal bracing members 90 may be considered to correspond to chords connecting the uprights 88 at their upper and / or middle regions. Bracing at least two of the uprights 88 at their upper and / or middle regions with at least one horizontal bracing member 90 forms at least one drag strut or collector, as is commonly known in the art. Drag struts, or collectors, are where at least two vertical uprights are braced by a horizontal beam at the top of the two uprights and function to collect and transfer diaphragm shear forces to the uprights. In addition to at least one horizontal brace member 90 extending between the uprights 88 of each prefabricated brace frame 86a, b, at least one diagonal brace member 92 can be connected to the uprights to provide additional stability to the prefabricated braced frame. The brace members 90, 92 extending between the uprights 88 are designed to function in tension and compression, similar to a truss. The braces between the uprights can be designed in different patterns, including cross braces, K-braces, V-braces, and / or eccentric braces. Cross braces, also known as X-braces, are made up of two diagonal brace members that cross each other. The brace members in a K-brace are arranged to form a K-shape between the uprights. In the particular embodiment of the invention shown in FIG. 13b, the pattern of brace members 90, 92 connecting the multiple uprights 88 of each of the prefabricated brace frames 86a, b shown in FIG. 16 employs a K-brace pattern to provide an A-frame.To provide the A-shaped frame, each of the plurality of prefabricated frames 86a,b includes two sets of diagonal braces 92: a first set of diagonal braces 92 in the upper portion of the prefabricated frame and a second set of diagonal braces 92 in the lower portion of the prefabricated frame. The set of diagonal braces 92 in the lower portion of the prefabricated frame extends from the horizontal braces toward the mid-region of the prefabricated frame to the bottom of the prefabricated frame to form legs 94 for mounting the prefabricated frame to the floor. The braces 90, 92 are fixedly connected to the uprights 88 by fasteners commonly known in the art, including, but not limited to, welds, bolts, rivets, or combinations thereof. Various lightweight materials can be used to prefabricate the frame, including, but not limited to, metal, plastic, or fiber-reinforced composites. Because the grid framework structure is primarily used to store grocery items, the type of metal used to construct the tote guides should be sufficiently corrosion-resistant. Examples of metals include, but are not limited to, stainless steel or galvanized steel. The uprights and / or brace members may be formed by folding a sheet metal blank at one or more creases, e.g., by metal stamping. To further increase the structural integrity of the prefabricated frame, one or more inserts may be used to strengthen the vertical members 88 and / or the horizontal brace members 90 and / or the diagonal brace members 92. For example, in the case of a C-shaped cross-sectional profile of the horizontal brace members, an insert (not shown) may be placed inside the C-shaped profile, so that the C-shaped profile forms an envelope around the insert.

[0072] The plurality of prefabricated frames 86 a, b are arranged in a three-dimensional grid pattern as shown in FIG. 16 in that the prefabricated frames comprise a first set 86 a of parallel prefabricated frames and a second set 86 b of parallel prefabricated frames. The first set 86 a of parallel prefabricated frames extends in a first direction, and the second set 86 b of parallel prefabricated frames extends in a second direction, the second direction being substantially perpendicular to the first direction, such that the plurality of prefabricated frames are arranged in a grid pattern comprising a plurality of modular storage cells or spaces 96. The first and second directions may correspond to the X and Y axes of a Cartesian coordinate system. Each of the plurality of prefabricated frames 86 a, b is sized such that each of the modular storage cells 96 is sized to store a plurality of stacks of storage containers, commonly known as storage bins. Connection of adjacent prefabricated frames 86 a, 86 b in the support framework structure 82 involves connecting one of the uprights 88 of the prefabricated frame 86 a extending in a first direction to one of the uprights 88 of the adjacent prefabricated frame 86 b extending in a second direction, as best shown in FIG. 18. Various fasteners or attachments known in the art may be used to connect adjacent prefabricated frames together, including, but not limited to, bolts, riveting, welding, or even the use of a suitable adhesive.

[0073] To guide one or more robotic load handling devices on the support framework structure 82, the track system 84 is mounted to the support framework structure 82 such that the track system 84 extends across a plurality of modular storage cells 96 formed by a plurality of prefabricated frames 86 a, b. The track system 84 comprises a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells (see FIG. 27). More specifically, a first set 122 a of parallel tracks extends in a first direction and a second set 122 b of parallel tracks extends in a second direction, the second direction being substantially perpendicular to the first direction to adopt the grid-like pattern (see FIGS. 27 and 29). Each of the plurality of modular storage cells 96 of the support framework structure 82 is sized to accommodate a plurality of stacks of storage containers, such that each modular storage cell 96 of the support framework structure 82 is sized to accommodate a subgroup of two or more grid cells of the track system 84.

[0074] The plurality of modular storage cells 96 of the supporting framework structure 82 shown in FIG. 16 create a plurality of storage spaces for storing a plurality of stacks of storage containers within each storage space of the supporting framework structure, i.e., an open storage space for storing a plurality of stacks of storage containers. In a specific embodiment of the present invention, shown in top views of a grid framework structure in FIGS. 26 and 28, each of the plurality of modular storage cells 96 of the supporting framework structure 82 is sized to accommodate 20 grid cells 42 of the track system 84, i.e., a grid pattern of 5 by 4 grid cells. Thus, each modular storage cell 96 of the supporting framework structure 82 provides storage space for storing 12 stacks of storage containers. The size of each of the plurality of modular storage cells is not limited to accommodating 20 grid cells of the track system, but can be a plurality of grid cells of the track system, i.e., each modular storage cell 96 can accommodate a grid pattern of X by Y grid cells, where X and Y can be any number greater than or equal to 1. In other words, the ratio of the number of grid cells 42 of track system 84 per modular storage cell 96 of supporting framework structure 82 is X:1, where X is any integer greater than 1; i.e., each of the plurality of modular storage cells 96 of supporting framework structure 82 is sized to support a subset of the plurality of grid cells 42 of track system 84, the subset comprising two or more grid cells 42 of track system 84.

[0075] The grid framework structure 80 further includes a plurality of tote guides 98 for guiding one or more storage containers as they are lifted by a robotic load handling device operable on the track system 84 from one or more stacks of storage containers stored in the modular storage cells 96 of the support framework structure 82 through respective grid cells 42 of the track system 84. Each tote guide 98 of the plurality of tote guides includes two vertical container guide plates extending between the track system and the floor (see FIG. 38) for engaging each corner of the storage container as it is guided toward a given grid cell 42. The two vertical container guide plates are configured to accommodate grabber devices and / or corner sections of the storage container. To guide the storage container through the grid cell as it is lifted by a robotic load handling device operable on the track, the tote guides extend between the floor and a node where the multiple tracks intersect in the track system (see FIGS. 13a and 39).

[0076] A plurality of tote guides 98 extend from one or more nodes where the plurality of tracks intersect in the track system to the floor so that storage containers are guided along the tote guides and through the grid cells of the track system. A plurality of tote guides are disposed in each of the modular storage cells of the supporting framework structure to form a plurality of storage columns for storing a plurality of stacks of storage containers within each of the plurality of modular storage cells. Typically, the plurality of tote guides are disposed such that all four corners of a given storage container are guided through the grid cells, i.e., each storage column includes four tote guides for engaging with the four corners of a given storage container in the stack, as shown in FIG. 7 . It may not be necessary to engage or receive all four corners of a storage container along the tote guides to provide lateral stability to the storage container as it is lifted toward the track system by the lifting mechanism of the load handling device. 35, a plurality of tote guides 98 are positioned to engage only one pair of diagonally opposed corners of the grabber device and / or container, i.e., the grabber device and / or container are guided by engaging the tote guides at their diagonally opposed corners. This provides the grabber device and container with a level of lateral stability in the X and Y directions as the container is lifted along the diagonally opposed guides, each of which accommodates a diagonally opposed corner of the storage container.Therefore, compared to having tote guides at all of the nodes of the grid structure, in the specific embodiment of the invention shown in FIG. 35, multiple tote guides 98 are positioned at alternating nodes in a first direction (e.g., the X direction) and a second direction (e.g., the Y direction) so that one or more containers are stacked between and guided by only two tote guides. That is, a first set of tote guides 98 is positioned at alternating nodes in the first direction (e.g., the X direction) and a second set of tote guides 98 is positioned at alternating nodes in the second direction (e.g., the Y direction) so that one or more containers are stacked between and guided by only two tote guides. By having tote guides at alternate nodes or intersections, half as many tote guides would be needed to guide grabber devices and / or storage containers through the grid cells. Additionally, grabber devices and storage containers are accommodated at only two of the corners of the grid cells when they are lifted toward them. The spatial arrangement of tote guides 98 for guiding each of the storage containers toward the grid structure at only their diagonally opposed corners is shown in Figure 35. Reducing the number of tote guides required to guide the storage containers through the grid cells contributes to a reduction in the number of components required to erect a support framework structure in accordance with the present invention.

[0077] Compared to traditional stick-built approaches of grid framework structures in which tote guides are incorporated into largely load-bearing vertical uprights to support a track system and one or more robotic load handling devices operable thereon, the tote guides do not necessarily need to be load-bearing. This is because the weight of the track system and one or more robotic load handling devices operable thereon is supported by the prefabricated frames 86 a, b arranged to form the support framework structure 82 discussed above. As a result, the tote guides 98 can be fabricated from lower-cost materials and / or processes. In certain embodiments of the present invention, each of the plurality of tote guides 98 is formed from a sheet metal blank 100 with parallel folds 102 extending along the longitudinal length of the sheet metal blank. The sheet metal blank is folded along the folds to form two substantially vertical container guide plates that define the two tote guides. The folded sheet metal blank, shown in Figures 36 and 38, has a substantially rectangular cross-sectional central portion 104 and flanges or lips 106 projecting from either side of the central portion 104 that cooperate with the walls of the central portion to define two tote guides. Another way to describe the forming process for the tote guides is to form substantially rectangular corrugations 104 in the sheet metal blank. An example of a forming process for manufacturing tote guides from folded sheet metal blanks is cold rolling. Due to the length of the tote guide, one or more stiffeners may be incorporated onto the folded sheet metal blank to prevent excessive deflection of the vertical container guide plates when guiding storage containers as they are lifted toward grid cells in the track system. The one or more stiffeners may comprise one or more ribs incorporated into the fabric of the sheet metal blank, more specifically, into the vertical container guide plates. Another means for providing one or more stiffeners in the tote guide is to brace the substantially rectangular portions or rectangular corrugations 104 of the folded sheet metal blank.

[0078] Two separate folded sheet metal blanks 100 can be used to form four tote guides for guiding the corners of four adjacent storage containers. As shown in FIG. 36, the two folded sheet metal blanks 100 are positioned directly opposite each other with their respective rectangular cross-sectional central portions 104 facing each other. Forming the tote guides 98 separately as a set of two tote guides also provides the benefit of accommodating a prefabricated frame shared between adjacent modular storage cells, as shown in FIG. 37. In FIG. 37, two sets of tote guides 98 are shown on either side of a common prefabricated frame 86a,b shared between adjacent modular storage cells, such that the common prefabricated frame 86a,b is sandwiched between the two sets of two tote guides. Only two guides are required at each node where the track supports intersect around the perimeter of the support framework structure.

[0079] According to an embodiment of the invention as shown in FIG. 39 , instead of using a cross-shaped cap plate as discussed above in FIG. 10 to secure the tote guide 98 to the node of the track system, the tote guide 98 is secured to the track support 56 at the node of the track system 84 by a cap 158 that is mounted on top of the tote guide 98 and includes one or more bolts and / or pins 108 as shown in FIG. 39 . In the particular embodiment of the invention shown in FIG. 39 , the cap 158 includes at least one locating pin 108 that is received in an opening 110 in the underside of the track support where the track support 56 intersects with the track support 56 at the node in the track system 84. The cap 158 is optionally secured to the top of the folded sheet metal blank of the tote guide by a snap fit, or is optionally welded to the top of the folded sheet metal blank. Like the tote guide, the cap 158 may optionally be formed from a sheet metal blank that is folded along multiple creases. The bottom of the tote guide 98 is secured to the floor by one or more anchor bolts (not shown). The tote guide is secured within the modular storage cell by tensioning the tote guide between the floor and the track system. The cap can optionally include tension bolts 112 for tensioning the tote guide between the track system and the floor. As shown in FIG. 39, the tension bolts are receivable within openings 110 where the track supports intersect at nodes in the track system. Nuts are used to tension the tote guide between the track system and the floor. The cap 158 additionally includes guide members 114, as shown in FIG. 39, that cooperate with the tote guide to prevent grabber devices or storage containers from getting stuck in the area where the track supports intersect at nodes in the track system. The guide members 114 are configured to cooperate with the track supports 56 to provide a guide surface for guiding totes through the grid cells of the track system.

[0080] While arranging the prefabricated frames in a three-dimensional grid pattern to form a support framework structure provides structural integrity to support a track system for one or more robotic load handling devices operable on the support framework structure, the direct contact of adjacent prefabricated frames in the support framework structure does not account for thermal expansion of the prefabricated frames. In this case, the uprights or vertical members 88 of adjacent prefabricated frames in the support framework structure are directly connected together, for example, by one or more fasteners, at the joints between adjacent modular storage cells so that the uprights or vertical members abut one another. When prefabricated frames are rigidly fastened to the floor and directly connected to one another in the support framework structure, forces resulting from thermal expansion in one or more structural components of one prefabricated frame are transferred to adjacent or neighboring prefabricated frames in the support framework structure. Thermal expansion in each prefabricated panel is largely concentrated along the horizontal braces or drag struts between the vertical uprights. The expansion of the horizontal brace members 90 results in forces being generated in the horizontal direction, which can be evidenced by the arrows in the drawings of the sections of the supporting framework structure shown in Figures 14(a) and 14(b).

[0081] FIG. 14(a) is an example of the expansion of horizontal brace members 90 at high temperatures, as indicated by the arrows on adjacent prefabricated frames, and FIG. 14(b) is an example of the effect of contraction of horizontal brace members 90 between vertical uprights 88 as a result of lower temperatures. When prefabricated frames are in direct contact, the forces resulting from the expansion and / or contraction of horizontal brace members 90 in one prefabricated frame are transferred to the vertical uprights 88 of a neighboring prefabricated frame. In both examples shown in FIGS. 14(a) and 14(b), the cumulative effect of the expansion and / or contraction of horizontal brace members 90 results in distortion of the prefabricated frames, as indicated by the dashed lines. When a track system is secured to a supporting framework structure, distortion of the prefabricated frames can result in dimensional distortion of at least a portion of the track system, particularly one or more grid cells of the track system. Because the robotic load handling devices are operable on a track system, distortion of at least a portion of the track system may cause one or more robotic load handling devices operable on the track system to derail, or in the worst case, tip over on the track system.

[0082] To mitigate the effects of thermal expansion in one prefabricated frame, which may affect adjacent prefabricated frames in the supporting framework structure and cause distortions in the shape of the supporting framework structure, the vertical uprights 88 of adjacent prefabricated frames 86a,b connected in the first and / or second directions are spaced apart. The spacing between the connecting vertical uprights of adjacent prefabricated frames is such that elastic deformation of the vertical uprights of the adjacent prefabricated frames as a result of thermal expansion is intentionally induced, reducing the transmission of forces to adjacent prefabricated frames in the supporting framework structure. This can be clearly demonstrated by the illustrations shown in Figures 15(a) and 15(b), where Figure 15(a) is an example of the expansion of horizontal bracing members at high temperatures, indicated by arrows on adjacent prefabricated frames, and Figure 15(b) is an example of the effects of contraction of horizontal bracing members between vertical uprights at lower temperatures. 14(a), the spacing between adjacent prefabricated frames, particularly between adjacent vertical uprights, allows the connecting vertical uprights of adjacent prefabricated frames to intentionally elastically deform in the space available between the adjacent prefabricated frames, as shown in FIG. 15(a), limiting the transmission of forces to neighboring prefabricated frames. This has the effect of weakening or absorbing the transmission of forces between neighboring prefabricated frames. In other words, the forces resulting from the thermal expansion of the horizontal bracing members 90 between the vertical uprights in one prefabricated frame are absorbed by the distortion of the vertical uprights rather than being transmitted to neighboring prefabricated frames.

[0083] The strain pattern of the vertical uprights depends on the distribution of the spacing between adjacent horizontal braces of adjacent prefabricated frames. This is because the forces between adjacent prefabricated frames as a result of thermal expansion are largely concentrated in the region of the horizontal braces of the adjacent prefabricated frames. Therefore, the spacing between adjacent horizontal braces between adjacent prefabricated frames decreases as the horizontal braces thermally expand, as shown in Figure 15(a). In some cases, the distal ends of the horizontal braces of adjacent prefabricated frames butt against each other as a result of thermal expansion, which is relieved by the strain of the vertical braces between the horizontal braces. Depending on the orientation of the prefabricated frames in the supporting framework structure, the forces as a result of thermal expansion of the horizontal braces are largely along the first, or X, direction and / or the second, or Y, direction. Because the vertical uprights of adjacent prefabricated frames are spatially distributed, the strain of the vertical uprights of adjacent prefabricated frames has the effect of distributing the thermal expansion forces among the multiple prefabricated frames.

[0084] A similar effect of absorbing the thermal expansion of horizontal bracing members between vertical uprights due to distortion of the vertical uprights applies to the contraction of horizontal bracing members in one or more prefabricated frames at lower temperatures (e.g., refrigeration or freezer temperatures), as shown in FIG. 15(b). In this case, the contraction of horizontal bracing members 90 pulls the connection points with vertical uprights 88, causing the vertical uprights to elastically distort, as shown in FIG. 15(b). Because the vertical uprights of adjacent prefabricated frames connected in the first and / or second directions are spaced apart, distortion of the vertical uprights is accommodated by the spacing between adjacent vertical uprights of adjacent prefabricated frames. The spacing between adjacent vertical uprights of adjacent prefabricated frames is sufficient to allow one or both of the adjacent vertical uprights to deform elastically rather than plastically. In order to allow elastic deformation of the vertical uprights of adjacent prefabricated frames, the spacing between adjacent vertical uprights of adjacent prefabricated frames may be in the range of 5 mm to 120 mm, preferably 10 mm to 120 mm. In all cases, the spacing between adjacent vertical uprights of adjacent prefabricated frames is such that thermal expansion forces between neighboring prefabricated frames are much more attenuated or absorbed rather than transmitted to the neighboring prefabricated frames.

[0085] Various spacers 93 may be used to space adjacent prefabricated frames in the supporting framework structure, including, but not limited to, the use of washers having different thicknesses to control elastic deformation, as shown in Figures 15a and 15b. The spacing between adjacent vertical uprights of adjacent prefabricated frames may be controlled by the width of the spacers 93 between the adjacent vertical uprights. The spacers 93 may be permanently installed between adjacent vertical uprights, or alternatively, may be used to space adjacent vertical uprights of adjacent prefabricated frames and then subsequently removed to leave a gap between the adjacent vertical uprights.

[0086] The distribution of a plurality of spacers 93 between vertical uprights 88 connected at joints between adjacent prefabricated frames in a supporting framework structure is shown in FIG. 15c. In a specific embodiment of the invention, the spacers 93 shown in FIGS. 15d and 15e comprise a first spacing member or portion 93b extending in a first direction along axis XX and a second spacing member or portion 93c extending in a second direction along axis YY, with the first spacing member 93b shown to be longer than the second spacing member 93c. As a result of the different spacing lengths of a given spacer 93, the spacing of the vertical uprights 88 at joints between adjacent prefabricated frames extending in the first direction differs from the spacing of the vertical uprights at joints between adjacent prefabricated frames extending in the second direction. This is clearly shown by the connection of the vertical uprights 88 of four separate adjacent prefabricated frames in a supporting framework structure in FIG. 15d.

[0087] Of course, the number of connecting vertical uprights will vary depending on the position of the vertical uprights in the supporting framework structure. For example, there may be three connecting vertical uprights from three adjacent prefabricated frames at the edge of the supporting framework structure and two connecting vertical uprights at the corner of the supporting framework structure. The drawing shown in Figure 15d is a top view of connected vertical uprights within the interior of a supporting framework structure having four connecting vertical uprights. The first spacing members 93b space the connecting vertical uprights apart in the first direction X, and the second spacing members space the connecting vertical uprights apart in the second direction Y.

[0088] In certain embodiments of the invention, the first spacing members space the connecting vertical uprights a distance in the range of 50 mm to 120 mm in the first direction, and the second spacing members space the connecting vertical uprights a distance in the range of 10 mm to 30 mm in the second direction. The difference in spacing length is due to the placement of the connecting vertical uprights in the supporting framework structure and preventing any portion of the vertical uprights from protruding into the grid cells of the track system. The shorter spacing member, i.e., second spacing member 93c, connects the vertical uprights closer together in the second direction compared to the vertical uprights connected in the first direction, thus reducing the protrusion of any portion of the vertical uprights, particularly the portion connected in the second direction, into the storage column or grid cell. The difference in spacing between the vertical uprights connected in the first direction and the vertical uprights connected in the second direction can also control the deflection of the vertical uprights in the first direction and the vertical uprights connected in the second direction, with greater deflection of the connected vertical uprights occurring in the first direction than the vertical uprights connected in the second direction. However, the present invention is not limited to the spacing of the vertical uprights connected in the first direction being different from the vertical uprights connected in the second direction, and can be substantially equal in length in both the first and second directions, depending largely on the cross-sectional profile of the vertical uprights.

[0089] To install the spacer 93 between the vertical uprights 88, the spacer 93 includes one or more openings 95a, 95b, and 95c extending in a first direction and a second direction for receiving one or more bolts. In a specific embodiment of the invention shown in FIG. 15e, the spacer 93 is formed as a single, integral body having a first spacer member or portion 93b extending in the first direction and a second spacer member or portion 93c extending in the second direction. The spacer 93 may be formed by molding, casting, or additive manufacturing (3D printing) and may be formed from a variety of rigid materials, including, but not limited to, metal, plastic, or ceramic. In a specific embodiment of the invention, the spacer 93 is formed by casting, and if the grid framework structure is used to store food, the spacer is cast from a food-safe material, such as stainless steel. Stainless steel is used to cast the spacer to ensure that the spacer does not contaminate the food being stored. However, problems with using stainless steel to cast the spacers include the cost of casting the spacers due to the intricate detail of the spacers and the need to ensure consistent dimensional tolerances of the spacers in the first and second directions and from one connection to another across the supporting framework structure. In certain embodiments of the present invention, the spacers 93 are cast using a lost wax process or a similar process, such as a water glass casting process. Forming the spacers as a single, integral body improves efficiency and thus contributes to lowering the cost of assembly of a grid framework structure in accordance with the present invention.

[0090] Also shown in Figure 15e is a flange 99 at the distal end of the first spacer member extending in the first direction. The flange 99 is shaped to abut the outer surface of the vertical upright 88 when positioned between adjacent vertical uprights (see Figure 15d). An opening 95c extends through the first spacer member 93b and through the flange 99. When installed between the vertical uprights, a bolt is received in the opening in the spacer and extends through the wall of the vertical upright in a direction along axis XX, as shown in Figure 15d. Tightening the bolt compresses the vertical upright against the flange, forming a secure connection between the vertical upright and the spacer. The cross-sectional profile of the vertical upright connected to the spacer also allows for flexure of the vertical upright relative to the spacer. In contrast to the first spacer member 93b, the second spacer member 93c has two openings 95a, 95b for receiving two bolts, a first opening 95a above the first spacer member and a second opening 95b below the first spacer member. The second spacer member is connected in a second direction and abuts against the outer surfaces of the connected vertical uprights via holes 89 in the vertical uprights (see Figure 13c).

[0091] The location of spacers 93 between adjacent vertical uprights 88 of adjacent prefabricated frames can also control the degree of deformation of the vertical uprights 88. Because expansion occurs largely along the horizontal braces, one or more spacers are positioned between the horizontal braces to cause distortion of the vertical uprights 88. As shown in FIG. 15c, multiple spacers 93 are distributed at regular intervals longitudinally along the vertical uprights to provide controlled deflection of the vertical uprights during movement of the prefabricated frame as a result of thermal expansion. In both options, it is essential that spaces exist between adjacent vertical uprights of neighboring prefabricated frames to allow elastic deformation of one or more of the vertical uprights without severely distorting the overall shape of the supporting framework structure.

[0092] To introduce spacing between adjacent vertical uprights of adjacent prefabricated frames in the supporting framework structure, in certain embodiments of the present invention, the supporting framework structure is subdivided into a plurality of modular units or blocks, where each of the plurality of modular units or blocks can function as a separate, stand-alone unit, allowing the modular units to move independently of one another within the supporting framework structure. Each of the plurality of modular units corresponds to a single modular storage cell when the modular units are assembled together. Subdividing the supporting framework structure into a plurality of modular units not only facilitates construction of the supporting framework structure, but also provides flexibility to space one or more adjacent vertical uprights of adjacent prefabricated frames to accommodate the thermal expansion effects discussed above. To space adjacent vertical uprights in the supporting framework structure, the plurality of prefabricated frames are arranged in a grid pattern comprising a plurality of modular storage cells, such that adjacent modular storage cells share a common prefabricated frame 126. This can be clearly seen by the isometric views of multiple modular units to form four modular storage cells 96 shown in Figures 16 and 35, and the top view of the arrangement of prefabricated frames forming the individual modular units shown in Figure 17.

[0093] Because the geometry of each of the modular storage cells in the supporting framework structure 82 is rectilinear, three types of modular units are used that are configured to couple with one another to provide a supporting framework structure in which each of the modular units shares a common prefabricated frame 126 between adjacent modular storage cells. The three types of modular units are shown in Figures 19-27, and each of the three types of modular units has a respective coupling portion 124 that allows the modular unit to couple with an adjacent modular unit in either a first orientation and / or a second orientation in the supporting framework structure such that adjacent modular storage cells share a common prefabricated frame therebetween. To couple the three modular units together to form a closed plurality of modular storage cells that share a common prefabricated frame between adjacent modular storage cells, one of the three modular units is a closed-sided modular unit and the other two modular units are open-sided modular units having an open side along at least one side of the modular unit. At least one open side of the open-sided modular unit is closed by mating with a side of an adjacent modular unit in the supporting framework structure. For purposes of defining this invention, the three different types of modular units will be referred to as a first type modular unit 116, a second type modular unit 118, and a third type modular unit 120. The second and third type modular units 118, 120 are open-sided modular units having at least one open side configured to mating with one or more sides of adjacent modular units in the supporting framework. The sides of each modular unit are formed from a prefabricated frame, so that adjacent modular units share a common prefabricated frame.

[0094] 17, to assemble a support framework structure in which the first, second, and third type modular units 116, 118, 120 share a common prefabricated frame 126 between adjacent modular storage cells, the first type modular unit 116 comprises four prefabricated frames arranged in a linear configuration to form a closed modular unit, the second type modular unit 118 comprises three prefabricated frames arranged in a substantially U-shaped configuration to form an open modular unit along one side of the modular unit, and the third type modular unit 120 comprises two prefabricated frames arranged in a substantially L-shaped configuration to form an open-sided modular unit along two sides of the modular unit. As shown in FIGS. 16 and 17, the assembly of the first, second, and third type modular units 116, 118, 120 forms at least four closed modular storage cells that share a common prefabricated frame 126 between adjacent modular storage cells. FIG. 17 also illustrates, in exaggerated form, that adjacent modular units 116, 118, 120 are intentionally spaced apart so that each behaves as a stand-alone modular unit that can move independently relative to one another within the supporting framework structure to accommodate thermal expansion within their respective modular units. The spacing between adjacent modular units accommodates elastic deformation of adjacent vertical uprights 88 as a result of thermal expansion, which is significantly cushioned by adjacent vertical uprights of adjacent prefabricated frames within the supporting framework structure. To provide sufficient spacing for elastic deformation of one of the adjacent vertical uprights, the spacing between adjacent vertical uprights is within the range of 50 mm to 120 mm in the first direction and 10 mm to 30 mm in the second direction. The modular units that make up the four modular storage cells shown in FIG. 17 are assembled from a single first-type modular unit 116, two second-type modular units 118, and a single third-type modular unit 120.A first type modular unit 116 is shown mating with two second type modular units 118 in each of the X and Y directions. A single third type modular unit 120 matings with two second type modular units 118 in both the X and Y directions.

[0095] 18-27 are schematic diagrams illustrating the assembly process of a grid framework structure according to an example of the present invention, such that adjacent modular storage cells share a common prefabricated frame. The prefabricated panels are typically presented as flat packs that can be easily transported to the construction site, which may be a warehouse or an existing building. Construction involves the gradual construction of a supporting framework structure from multiple prefabricated frames, as clearly illustrated in FIGS. 18-27. Assembly of the supporting framework structure begins with constructing a first modular unit 116 from four prefabricated panels 86a, 86b. For purposes of illustration, the four prefabricated frames of the first modular unit 116 will be referred to as first prefabricated frame 128a, second prefabricated frame 128b, third prefabricated frame 128c, and fourth prefabricated frame 128d. Prior to fastening the second prefabricated frame 128b to the first prefabricated frame 128a, one or more 90° angle brackets (or stands) 130 may be used to ensure that the first prefabricated frame 128a is substantially perpendicular (in a different vertical plane) to the first prefabricated frame 128b, i.e., so that the first prefabricated frame 128a extends in the X direction and the second prefabricated frame 128b extends in the Y direction. The 90° angle brackets function as stands to ensure that the first prefabricated frame remains substantially vertical when the second prefabricated frame 128b is fastened to the first prefabricated frame 128a via their respective adjacent vertical uprights. The 90° angle bracket 130 shown in FIG. 18 is in the form of a right-angle frame. Two 90° angle brackets 130 are secured to the vertical uprights of the first prefabricated frame 128a. Securement of the first prefabricated frame to the second prefabricated frame involves fastening their respective vertical uprights together with fasteners known in the art. A variety of fasteners may be used to secure the first prefabricated frame to the second prefabricated frame.These include, but are not limited to, various bolts, screws, rivets, etc. Other fastening methods include the use of adhesives or welding. The spacers 93 described above can be used to ensure that the first prefabricated frame 128a is spaced apart from the second prefabricated frame 128b in a first direction and a second direction to accommodate thermal expansion of their respective horizontal bracing members. Multiple spacers 93 can be spatially distributed between adjacent vertical uprights of adjacent prefabricated frames to control deformation or distortion of at least one of the adjacent vertical uprights during thermal expansion. In the example shown in Figures 15(a) and 15(b), two spacers 93 are shown connected between vertical uprights 88 to control distortion or deflection of the vertical uprights of adjacent prefabricated frames. However, the present invention is not limited to two spacers between adjacent vertical uprights, but can also include multiple spacers between adjacent vertical uprights. Ideally, spacers are positioned between the horizontal braces connecting the vertical uprights together in a given prefabricated frame so that the strain on the vertical uprights is concentrated in the area between the horizontal braces, as shown in Figures 15(a) and 15(b).

[0096] In addition to fastening or connecting the prefabricated frames to one another, each of the prefabricated frames is secured to the floor by one or more fasteners (not shown). To facilitate fastening each of the multiple prefabricated frames to the floor, each of the prefabricated frames is secured to the floor using one or more fasteners (e.g., anchor bolts) via their respective legs 94 discussed above. The third prefabricated frame 128c and the fourth prefabricated frame 128d are then fastened to the first prefabricated frame 128a and the second prefabricated frame 128b to form a linear or square-shaped structure that forms the first modular unit 116 as shown in FIG. 19. FIG. 19 also shows that the legs 94 of adjacent prefabricated frames join to form a three-dimensional stable structure.

[0097] Each of the first, second, third, and fourth prefabricated frames is secured to the floor via their respective legs 94 by one or more fasteners, such as anchor bolts, to form a stable, free-standing structure. Once the first type modular unit 116 is secured to the ground, the second type modular unit 118 and the third type modular unit 120 are then assembled around the first type modular unit, as the first type modular unit provides a stable structure for securing the prefabricated frames of the second type modular unit 118 and the third type modular unit 120 to the first type modular unit 116. The first type modular unit 116 can serve as a building origin, and other modular units, i.e., the second type modular unit 118 and the third type modular unit 120, are then assembled around the origin to expand the number of modular storage cells of the supporting framework structure in the X and Y directions. Thus, when constructing a grid framework structure according to examples of the present invention, construction of the supporting framework structure begins with assembling an origin before other modular units are assembled on the origin. Similar to the first type modular unit, the second and third type modular units are assembled around the origin by separately fastening prefabricated frames to the vertical uprights of the first type modular unit to extend the supporting framework structure in the X and Y directions. For example, as shown in FIG. 22 , a second type modular unit 118 is assembled on a first type modular unit 116 by connecting three prefabricated frames to one side of the first type modular unit 116 in a substantially U-shaped configuration to form two modular storage cells that share a common prefabricated frame 126 between adjacent modular storage cells.

[0098] To create a support framework structure with three modular storage cells, an additional second-type modular unit 118 is assembled on another side of the first-type modular unit by connecting three prefabricated frames in a substantially U-shaped configuration, as shown in FIG. 25, to form a substantially L-shaped support framework structure with three modular storage cells 96. To form a linear-shaped support framework structure 82 with four modular storage cells 96, the layout of the first and second-type modular units is such that the resulting support framework structure is completed by connecting two prefabricated frames in an L-shaped arrangement to form a third-type modular unit 120, as shown in FIG. 26. In each of the structures, there is a set 86a of parallel prefabricated frames extending in a first direction (i.e., the X-direction) and a set 86b of parallel prefabricated frames extending in a second direction (i.e., the Y-direction), such that the first and second sets of prefabricated frames are arranged in a grid pattern with a plurality of modular storage cells 96. The joints 124 in each of the modular units are such that adjacent modular storage cells in the structure share a common prefabricated frame 126 in the X and Y directions; i.e., a U-shaped second-type modular unit joins with a side of a first-type modular unit, and an L-shaped third-type modular unit joins with two sides of an adjacent U-shaped second-type modular unit in the structure of the supporting framework structure. This process is repeated to expand the supporting framework structure with multiple modular storage units. By building the supporting framework structure from individual prefabricated frames starting with a first-type “origin” modular unit 116, the shape of the supporting framework structure 82, and hence the number of modular storage cells 96, can be made flexible and depends largely on the number of second- and third-type modular units 118, 120 assembled on the first-type “origin” modular unit 116.In all cases, construction begins with constructing a "home" to create a stable structure for the installation of the second and third type modular units 118, 120. Once assembled, the modular units function as stand-alone units that can move independently relative to one another due to the spacing between or among adjacent prefabricated frames. In all cases, and to ensure there is room for deflection of the vertical uprights as a result of the effects of thermal expansion, assembly of the second and third type modular units 118, 120 to the first type modular unit 116 involves connecting their respective vertical uprights of adjacent prefabricated frames in a first direction and a second direction using the spacers discussed above.

[0099] The support framework structure 82 is configured to support a track system 84 comprising a plurality of tracks 122 a, 122 b for guiding movement of one or more robotic load handling devices on the support framework structure. To support the plurality of tracks 122 a, 122 b for guiding movement of the one or more robotic load handling devices on the support framework structure, the track system 84 according to an embodiment of the present invention further comprises a track support structure 156 comprising track supports 156 a, 156 b extending in a first direction and a second direction, the plurality of tracks 122 a, 122 b being configured to be mounted to the track support structure 156. In the particular embodiment of the invention shown in Figures 29-34, the plurality of tracks 122a, 122b are subdivided into a plurality of track sections 132, each track section 132 formed as a single, integral body and including track elements or portions 134, 136 extending toward the underlying track supports 156a, 156b to provide a track surface extending in a first direction and a second direction; i.e., each track section 132 has transversely extending connecting portions or elements 134, 136. For purposes of describing the invention, the connecting portions or track section elements 134, 136 may be referred to as "branches" extending transversely from the nodes 50. Further details of the assembly of the plurality of tracks onto the track support structure are discussed below.

[0100] Various fasteners known in the art may be used to secure the track support structure 156 to the supporting framework structure 82. These include, but are not limited to, various screws, nuts and bolts, rivets, etc. The track support structure 156 is secured to horizontal brace members 90 of one or more prefabricated frames 86 a, b in the supporting framework structure. Without provisions to accommodate movement of one or more of the modular units of the supporting framework structure as a result of thermal expansion, one or more areas of the track support structure 156 secured to the supporting framework structure may distort, which ultimately causes distortion of the entire track system 84. In addition to distortion of the track system as a result of movement of one or more of the modular units relative to one another in the supporting framework structure, any one of the components of the track system itself may also thermally expand or contract relative to the supporting framework structure. For example, when the track support structure 156 is secured to the supporting framework structure 82, a thermal expansion imbalance may exist between the supporting framework structure 82 and the track system 84. Moreover, the fixed interconnection of the track supports at their intersections in the grid pattern limits movement of the track supports relative to one another, thereby amplifying distortion of the track support structure. For purposes of defining this invention, "fixed" interconnection of the track supports at their intersections is interpreted to mean no movement of more than 0.5 mm. As discussed above, measures are taken to mitigate thermal expansion of the prefabricated frames of the support framework structure by spacing adjacent prefabricated frames from one another, but further measures may need to be taken to accommodate thermal expansion in one or more areas of the track system 84. To accommodate movement of one or more of the modular units 116, 118, 120 in the support framework structure 82, the track support structure 156 is also subdivided into a plurality of individual modular subframes, each of which comprises at least a portion of the track support structure 156, i.e., is sized to correspond to a subgroup of two or more grid cells of the track system.To allow the individual modular subframes to move relative to one another along a substantially horizontal plane in the track system, the modular subframes are interconnected by one or more sliding or movement joints 146 at joints 124 between adjacent modular storage cells 96 (see FIG. 24 ). This allows adjacent modular subframes to move relative to one another along a substantially horizontal plane via one or more of the sliding joints in the X direction (first direction) and the Y direction (second direction). While the interconnections of the track supports at their intersections within a given modular subframe are rigidly connected together by one or more bolts, the interconnections of the track supports at the joints between adjacent modular storage cells include one or more movement joints to allow relative movement between adjacent modular subframes. This allows for movement at the joints between adjacent modular subframes during movement of the track support structure due to thermal expansion, compared to the interconnections at the track support intersections within modular subframes that are rigidly connected together. For purposes of defining this invention, movement between adjacent modular subframes is understood to mean movement greater than 0.5 mm, i.e., movement within the range of 0.5 mm to 10 mm. The extent of movement of the modular subframes is highly dependent on temperature changes in the track system. Typically, the prefabricated frame is secured to the floor by one or more anchor bolts such that the vertical members at the joints between adjacent modular storage cells are spaced apart. To accommodate thermal expansion of the modular subframes, one or more slip joints at the joints between adjacent modular subframes allow movement within the range of 0.5 mm to 10 mm, preferably 0.5 mm to 5 mm.

[0101] To allow different portions of the track support structure 156 to move independently relative to one another at the junctures of adjacent modular storage cells of the supporting framework structure, and because the track support structure 156 is secured directly to the supporting framework structure, the track support structure 156 is sub-divided in a pattern similar to the sub-divisions of the supporting framework structure 82. Similar to the modular units 116, 118, 120 of the supporting framework structure 82 discussed above, each of the plurality of modular sub-frames has a coupling portion 138 configured to couple with adjacent modular sub-frames in the track support structure such that adjacent modular sub-frames in the track support structure share a common side between the adjacent modular sub-frames. As clearly shown in the schematic top view of the truck support structure in FIG. 28 , the plurality of modular subframes include a first type modular subframe 140, a second type modular subframe 142, and a third type modular subframe 144 that adopt a similar coupling pattern to the modular units 116, 118, 120 of the support framework structure 82, i.e., the first type modular subframe 140, the second type modular subframe 142, and the third type modular subframe 144 each have respective coupling portions 138 configured to couple with each other. Each of the first type modular subframe 140, the second type modular subframe 142, and the third type modular subframe 144 is mounted to and / or secured to its respective modular units 116, 118, 120 of the supporting framework structure 82, i.e., the first type modular subframe 140 is mounted to the first type modular unit 116, the second type modular subframe 142 is mounted to the second type modular unit 118, and the third type modular subframe 144 is mounted to the third type modular unit 120. The spacing between adjacent vertical uprights of adjacent prefabricated frames will result in the spacing between adjacent modular subframes mounted to their respective modular units.In contrast to the separation between the vertical uprights, adjacent modular sub-frames are separated by a distance in the region of 1 mm to 5 mm, preferably 1 mm to 3 mm, and more preferably 1.5 mm to 2 mm to allow for thermal expansion and to allow the wheels of the load handling device to move across the joints between adjacent modular sub-frames without getting caught on the track support.

[0102] To couple the first, second, and third modular subframes 140, 142, 144 together to form the linear-shaped truck support structure 156, the first, second, and third types of modular subframes employ similar joint patterns as the modular units of the support framework structure; i.e., the first type of modular subframe 140 has a closed-sided exterior frame structure, while the second type of modular subframe 142 and the third type of modular subframe 144 have open-sided exterior frames along at least one side of the modular subframe. Similar to the second type of modular units 118 and the third type of modular units 120 of the support framework structure 82 discussed above, the second type of modular subframe 142 is a three-sided frame that forms a substantially U-shaped exterior frame structure with one open side (see FIG. 22 ), and the third type of modular frame 144 is a two-sided frame that forms a substantially L-shaped exterior frame structure with two open sides (see FIG. 26 ). The open sides of both the second and third type modular subframes 142, 144 expose the ends of the track supports.

[0103] The second type modular subframe 142 is configured to mate with the first type modular subframe 140 such that the second type modular subframe 142 shares a common side with the first type modular subframe 140, i.e., such that the open side frame of the second type modular subframe 142 is closed by sharing a side with the first type modular subframe 140. The third type modular subframe 144 is configured to mate with an adjacent second type modular subframe 142 in the track system 84 by sharing two sides with the second type modular subframe 142. The joints between adjacent modular subframes correspond to the joints between adjacent modular units in the supporting framework structure, i.e., adjacent modular storage cells of the supporting framework structure. Similar to the first type modular unit 116, the first type modular subframe 140 serves as the "origin" to which the second and third type modular subframes 142, 144 mate.

[0104] To accommodate the movement or slip joints 146 between adjacent modular subframes, one or more slip joints are installed or secured to the shared side between the adjacent modular subframes. Assembly of the track support structure 156 begins with installing a first type modular subframe 140, which represents the origin of the track support structure 156, to the first modular unit 116, as shown in FIGS. 20 and 21 . The first type modular subframe 140 is then secured to the first type modular unit 116. Securing the first type modular subframe 140 to the first type modular unit 116 involves securing the external frame structure of the modular subframe to the horizontal brace members 90 of the prefabricated frame. Various fasteners may be used to secure the first type modular subframe 140 to the first type modular unit 116, including, but not limited to, screws, nuts, bolts, and the like. Other means for fastening the first type modular subframe 140 to the first type modular units 116, such as adhesives, welding, etc., are acceptable in the present invention. Because the first type modular subframe 140 is a closed-sided modular subframe, one or more sliding or moving joints are mounted on one of the sides shared with an adjacent modular subframe.

[0105] Once the first type modular subframe 140 is installed and secured to the first type modular unit 116, the second type modular subframe 142 is then installed and secured to the second type modular unit 142, as shown in FIG. 22 . The same type of fasteners may be used to secure the second type modular subframe 142 to the second type modular unit 118, i.e., to the horizontal braces of the prefabricated frame. To enable the second type modular subframe 142 to mate with the first type modular subframe 140 when installed to the second type modular unit 118 to accommodate one or more slip joints 146 between the first type modular subframe 140 and the second type modular subframe 142, the one or more slip joints are configured to rest on exposed ends of track supports extending from the open sides of the second type modular subframe 142. In the particular embodiment shown in FIG. 23 , exposed ends of the track supports 156 a, b extending from the open side of the second-type modular subframe 142 are shown to be received in one or more slip joints 146 mounted to the side of the first-type modular subframe 140. An advantage of one or more slip joints resting on the ends of the track supports from adjacent modular subframes is the ease with which track support structures can be assembled together incorporating one or more slip joints between adjacent modular subframes. Because one or more slip joints are configured to rest on the exposed ends of the track supports from adjacent modular subframes, the second-type modular subframe 142 can simply be lowered in a substantially vertical direction onto the second-type modular unit 118 and then secured to the second-type modular unit 118, as shown in FIG. 22 . Not all of the exposed ends of the track supports of the second-type modular subframe 142 will be required to be rested on by slip joints 146.Optionally, only a portion of the exposed ends of the track supports of the second type of modular subframe will need to be rested on by one or more of the slip joints 146. In all cases, the slip or movement joints are configured to allow the modular subframe to be separately mounted to the supporting framework structure in a substantially vertical orientation.

[0106] In the particular embodiment of the invention shown in FIG. 23 , the exposed track supports forming the central portion of the second-type modular subframe 142 are supported by slip joints 146. However, the track supports of the second-type modular subframe 142 on the outside of the second-type modular subframe are coupled to the first-type modular subframe 140 by being fastened to the first-type modular subframe 140 by angle brackets 123. The angle brackets 123 ensure that the outside of a given modular subframe is fastened to an adjacent modular subframe in the track support structure 156, while the track supports forming the central portion of the modular subframe are supported to the adjacent modular subframe in the track support structure 156 by one or more slip joints 146. To allow the track support end secured to the angle bracket 123 to move in either a first, or X, direction or a second, or Y, direction depending on the orientation of the connection with the angle bracket, the angle bracket is fastened to the track support end by a bolt or screw received in a slot or elongated opening in the angle bracket, which allows the bolt or screw securing the track support end to move along the slot or elongated opening.

[0107] In the specific embodiment of the invention shown in FIG. 24 , each slip joint 146 comprises a cradle bracket having a base wall 148 for supporting the end of the track support and opposing side walls 150 for preventing excessive lateral movement of the individual track supports of the second type modular subframe 142 after installation to the cradle bracket 146. Movement of the end of the track support, and hence movement between adjacent modular subframes, occurs by the end of the track support sliding on the base wall 148 of their respective cradle bracket 146. The cradle bracket 146 is oriented so that the end of the track support can move in only one direction, which may be the first, or X, direction, or the second, or Y, direction. Optionally, to prevent the end of the track support from disengaging from the slip joint 146, the end of the track support may be secured to the respective slip joint, and more specifically, to the slip joint's base wall 148, by fasteners. In the particular embodiment of the invention shown in FIG. 24 , a base wall 148 of a slip joint 146 includes a slot or elongated opening 147 for receiving a bolt. The slot 147 is oriented to allow a track support engaged with the slip joint to move in a first, or X, direction or a second, or Y, direction. The elongated slot limits movement of the modular subframes relative to one another in either the first direction and / or the second direction. To prevent excessive movement of the modular subframes in the first and second directions, movement in the first and second directions is limited to a maximum of 10 mm, preferably 5 mm, to accommodate thermal expansion of the track system.

[0108] In contrast to resting exposed ends of track supports on a supporting framework structure to provide relative movement between adjacent modular subframes, in an alternative embodiment of the present invention, a slip or translation joint 146b comprises an elongated element forming a bridge member 146c spanning the joint between adjacent modular subframes, as shown in FIGS. 24b-24e. The bridge member 146c comprises a first end 146d configured to be fixedly connected to the track support of a modular subframe, as shown in FIG. 24b, and a second end 146e comprising a pin 146f receivable in an opening 157 in the track support of an adjacent modular subframe, as shown in FIGS. 24d and 24e. Similar to the cradle bracket, relative movement between adjacent modular subframes is effected by movement of the pin 146f in the opening 157 in the track support 156a of the adjacent modular subframe in either the X or Y direction. As with the first embodiment of the slip joint with a cradle bracket, movement of pin 146f in opening 157 is limited by the size of the opening in track support 156a. Opening 157 is slightly enlarged or elongated compared to pin 146f to limit pin movement in the opening to a maximum of 5 mm, preferably 3 mm, and more preferably between 1 mm and 2 mm, to accommodate thermal expansion of the track system. Bridge member first end 146d is secured to the track support with pin 146f at second end 146e facing upward. This allows adjacent modular subframes to be mounted to the supporting framework structure in a substantially vertical orientation when the pin is received in the opening in the track support of the adjacent modular subframe, as shown in Figures 24d and 24e.

[0109] As an alternative to or in addition to having the bridge member pins facing upward, the bridge member 146c can be connected across adjacent modular subframes after the modular subframes have been installed to their respective modular units on the supporting framework structure, as shown in FIG. 24b. In this case, the pins at the second ends of the bridge members face downward to be received in a substantially vertical orientation within the track support openings of the adjacent modular subframes. In both cases, the installation of the slip or movement joints on the modular subframes is substantially vertical. Like the cradle brackets, the bridge members can be formed from metal, such as stainless steel. However, the present invention is not limited to the movement or slip joints discussed above and can be any type of movement or slip joint that allows movement between adjacent modular subframes within a range of 0.5 mm to 10 mm.

[0110] The spacing between adjacent slip joints 146 corresponds to the spacing between adjacent parallel track supports 156 a, 156 b. Movement between adjacent modular units, in this case the first type modular unit 116 and the second type modular unit 118, as a result of thermal expansion is accommodated by movement of the exposed ends of the track supports along their respective slip joints 146. Depending on the size of the supporting framework structure and the number of modular storage cells occupied by the supporting framework structure, the process of installing the modular subframes of the track support structure 156 to the first and second type modular units 116, 118 discussed above is repeated for the other modular subframes, as shown in Figures 25 and 26.

[0111] 26 is an example illustrating the installation of the third type modular subframe 144 to the third type modular unit 120 by coupling along two open sides of its L-shaped open frame structure to complete the linear configuration of the track support structure 156 with four modular storage cells. Similar to the second type modular subframe 142, the third type modular subframe 144 is lowered onto the third type modular unit 120 so that the exposed ends of the track supports on each open side thereof couple with the second type modular subframe 142 by being received in cradle brackets 146 mounted on the sides of the second type modular subframe 142 as shown in FIG. 26 or by being connected to bridge members in accordance with the second embodiment of the slip joint shown in FIGS. 24(b-e).

[0112] Movement between adjacent modular subframes depends on the number of joints between them. For the second type modular subframe 142, the joints are configured to allow movement only along one direction, e.g., the X or Y direction, depending on the orientation of the cradle bracket or bridge member forming the slip joint 146 at the joint with the first type modular subframe 140. For the third type modular subframe 144, which has two joints, movement along two directions, e.g., the X and Y directions, is allowed due to the connection to adjacent modular subframes along two sides. As a result, the track support structure includes a first set of slip or translation joints to allow movement in the X direction between adjacent modular subframes 140, 142, 144, and a second set of slip or translation joints to allow movement in the Y direction between adjacent modular subframes 140, 142, 144. The directions of movement in the X and Y directions between adjacent modular subframes are indicated by arrows in FIG. 28. By coupling adjacent modular sub-frames along the X and Y directions, movement between adjacent modular sub-frames is permitted along both the X and Y directions in a substantially horizontal plane. The modularity of the support framework structure and the track support structure with similar coupling portions allows grid framework structures of different shapes and sizes to be assembled.

[0113] A track system would not be complete without multiple tracks for guiding one or more robotic load handling devices on the track system. Each track of the multiple tracks is profiled to either provide a single track surface to allow a single robotic load handling device to travel on the track, or to provide dual tracks to allow two load handling devices to pass each other on the same track. When the multiple tracks are profiled to provide a single track, the track includes opposing lips along the length of the track (one lip on one side of the track and another lip on the other side of the track) to guide or restrain each wheel from moving laterally on the track. When the multiple tracks are profiled as dual tracks, as illustrated in FIG. 32 , the track includes two pairs of lips 152 along the length of the track to allow wheels of adjacent robotic load handling devices to pass each other in both directions on the same track. To provide two pairs of lips, the track typically includes a central ridge or lip 154 ​​and lips 152 on either side of the central ridge 154.

[0114] Like the track support structure 156 discussed above, the plurality of tracks 122a, 122b includes a first set 122a of parallel tracks extending in a first direction and a second set 122b of parallel tracks extending in a second direction, the second direction being substantially perpendicular to the first direction to adopt a similar grid-like pattern of the track system. Because the plurality of tracks are mounted on the track support structure 156, the grid pattern of the plurality of tracks corresponds to the grid pattern of the track support structure. While certain embodiments describe the plurality of tracks being mounted on the track support structure, the plurality of tracks may optionally be integrated into the track support structure, in which case the plurality of tracks adopt similar subdivisions to the modular subframes of the track support structure 156 discussed above. In other words, each of the first, second, and third types of modular subframes 140, 142, 144 of the track support structure 156 includes a portion of the track integrated into its respective modular subframe.

[0115] Similar to the support framework structure and the track support structure, the tracks may be modularized into track sections 132 to facilitate assembly of the tracks on the track support structure. The cross-shaped nature of each of the track sections allows a one-to-one relationship to exist between each track section 132 and each of the track system's nodes 50, in the sense that only a single track section 132 occupies a single node of the track system, rather than at least two track sections as found in the prior art track system described above and shown in FIG. 8 . In other words, the intersection of track section elements 134, 136 of a given track section 132 corresponds to a node of the track system. Adjacent track sections in the track system are positioned such that their respective track section elements 134, 136 extend into the area between the track system's nodes 50, i.e., meet at a point 160 between the track intersections. More specifically, the distal ends 162 of the track section elements (branches) 134, 136 of adjacent track sections 132 meet in a region substantially halfway or midpoint between neighboring nodes 50 of the track system. This also improves the speed with which each of the track sections can be assembled onto the track support structure 156 when assembling multiple tracks onto the track support structure 156, because a single track section can be installed at each node 50 of the track support structure 156. For example, each adjacent track section can be installed on the underlying track support in a different orientation because the track sections are not limited to one particular orientation on the track support structure. In other words, due to the symmetry, e.g., rotational symmetry, of the track sections of the present invention, the track sections can be installed on the track support structure in multiple different orientations without affecting their ability to connect to adjacent track sections on the track support structure. In the context of the present invention, rotational symmetry is the ability to rotate a track section by an angle so that the rotated track section matches a non-rotated track section.When the grid cells are square (tracks of equal length in the X and Y directions), the rotational symmetry of the track sections is such that the angle of rotational symmetry is 90°, meaning that the track section can be rotated four times and still coincide with itself, i.e., an order of symmetry of four. When the grid cells are rectangular, the rotational symmetry of the track sections is order two. This has the advantage of reducing the number of differently shaped track sections required to assemble track for a substantial portion of the grid structure, i.e., eliminating the "jigsaw" effect where track sections have specific locations in the track system, thereby reducing the time to assemble the track onto the track support structure. In addition, because fewer tool designs are required to form the track sections of the present invention compared to prior art tracks, tooling costs for manufacturing the track sections will be significantly reduced.

[0116] The multiple track sections 132 are mounted to an underlying track support structure to provide a continuous track surface between adjacent track sections for one or more robotic load handling devices to travel on the grid framework structure 80. Modularizing the multiple tracks into multiple cross-shaped track sections also provides the ability to cover areas of the track support structure that are susceptible to unevenness. Areas in the track system that are susceptible to unevenness are at the nodes of the track system where multiple track supports intersect in the track support structure and / or between adjacent modular subframes. The area of ​​the track support structure between the nodes 50 is less susceptible to any differences in height variation of the interlocking track supports 156 a, 156 b compared to the nodes discussed above. Extending track section elements of adjacent track sections into the area between the nodes of the track system will be less affected by any irregularities in the underlying track support structure between the nodes 50. As a result, the area of ​​the track support structure between the nodes is substantially flat and uninterrupted.

[0117] Because the joints between adjacent modular subframes in the track support structure are configured with one or more slip joints to accommodate movement between modular units in the support framework structure as a result of thermal expansion, the joints between adjacent modular subframes are also prone to unevenness. For example, a small step in the track system between adjacent modular subframes can be created by separately mounting the tracks to each of the modular subframes of the track support structure so that adjacent tracks in the track system butt up and down at the joints between adjacent modular subframes of the track support structure. When a robotic load handling device approaches the joint / joint between adjacent modular subframes, the wheels of the robotic load handling device tend to catch or hit the edge of the track as the wheels traverse the joint. Although the vertical displacement of the wheels as the robotic load handling device moves across the joint is minimal, this vertical impact shock to the wheels is one of the major sources of noise and vibration for a moving robotic load handling device. In the worst case scenario, a wheel collision on the rail or track imparts wear and tear not only to the wheels or tires of the robotic load handling device but also to the tracks, to the extent that damage occurs to either or both of the wheels and the tracks. To mitigate the presence of steps in the track system, particularly at the joints between adjacent modular subframes of the track support structure, one or more track sections are mounted to the track support structure at the joints between adjacent modular subframes, so that one or more portions of a given track section extend across the joint (see FIG. 29). The cruciform nature of each of the track sections allows the track sections to be mounted to the track support structure at the joints between adjacent modular subframes, so that their respective track section elements extend across the joint, as the exposed ends of the track supports are positioned to be received in cradle brackets of slip joints mounted to the adjacent modular subframes at the joints.This has the effect of masking any imperfections or edges in the underlying track support structure and shifting any intersections between adjacent track sections to areas of the track system that are less susceptible to such height variations, i.e., between the nodes of the track system.

[0118] While having a cross-shaped track section helps mitigate unevenness in the underlying track support structure, the distal ends of the track section elements 134, 136 of adjacent track sections 132 are also susceptible to unevenness, especially when they meet between nodes. The distal ends of the track section elements 134, 136 create a step at the joint between adjacent track sections 132 that, if left unchecked, can cause vertical displacement of the wheels of a load handling device moving across the joint between the connecting adjacent track sections 132. To mitigate this step, the distal ends 162 of the track elements are mitered or tapered, as shown in FIGS. 32 and 33 . The distal ends 162 of the track section elements include at least one tapered edge that changes the traditional 90° angle cut to a substantially 45° angle cut edge. Thus, before the wheels of the load handling device roll completely over the edge of the first track section element, a portion of the wheels is already in contact with the mitered end of the second track section element. This provides a gradual transition of the adjacent track sections and prevents the wheels from sinking into any gaps between the distal ends of the adjacent track sections.

[0119] Referring to FIG. 13a, the grid framework structure 80 can be thought of as a free-standing linear assembly of prefabricated braced frames supporting a track system formed from intersecting horizontal track supports and tracks, i.e., a four-wall-shaped framework. As a result, differently shaped track sections are required to cover different areas of the track support structure 156. For purposes of explanation, the different areas of the grid structure can be referred to as corner sections 164, perimeter sections 166, and center sections 168. The corner sections 164 of the track sections provide two-way connections in the track system, the perimeter sections 166 of the track sections provide three-way connections in the track system, and the center sections 168 of the track sections provide four-way connections in the track system. The different areas of the track system where the track system 84 has a linear shape are illustrated in the sketch of the track section pattern in FIG. 34. The sketch of the track section pattern shown in FIG. 34 is not to scale and is for illustrative purposes only. The track sections 132 in the corner sections 164 of the track system 84 are shown with different shaded areas, and each of the corner track sections 164 has two track section elements 134, 136, i.e., two branches, extending respectively in the X and Y directions of the track system 84. The track sections 132 in the perimeter section 166 of the track system 84 are shown with different shaded areas. In the particular embodiment of the invention shown in Figure 34, each of the track sections 166 at the perimeter of the track includes three track section elements 134, 136, i.e., three branches. In the embodiment illustrated in FIG. 32, the track section 166 at the periphery may have two track section elements 134, 136 extending in opposite directions along a first direction and a third track section element 134, 136 extending in a second direction, or may have two track section elements 134, 136 extending in opposite directions along the second direction and a third track section element 134, 136 extending in the first direction.The track sections 166 in the perimeter section are not limited to having three track elements or branches 134, 136, but can include more than three track section elements, depending on whether the perimeter section extends across more than one node 50 in the track system 84. The node 50 corresponds to an area of ​​the track system 84 where the individual track section elements or branches 134, 136 intersect. For example, the perimeter section can include two track section elements extending in opposite directions along a first direction and multiple track elements, i.e., more than three branches, extending in a second direction to connect with or intersect with adjacent track sections 84 in the central section of the grid structure.

[0120] As is clearly evident in the schematic sketch shown in FIG. 34 , a significant portion of the track system is contained within the central section of the track system, where each of the track sections 132 is cross-shaped with track section elements 134, 136 branching or extending transversely, i.e., in a first direction (X) and a second direction (Y). In all of the differently shaped track sections 164, 166, 168 in the particular embodiment shown in FIG. 34 , there is a one-to-one relationship between each of the plurality of track sections and each of the nodes 50 of the track system 84. For example, there is a one-to-one relationship between the track section 164 and the nodes 50 at the corners of the track system. Similarly, there is a one-to-one relationship between each of the track sections 166 and each of the nodes 50 around the periphery of the track system.

[0121] However, the present invention is not limited to a one-to-one relationship between each of the multiple track sections and each of the nodes, as a single track section can extend across more than one node in the track system. For example, one or more branches or track elements 134, 136 of a track section 132 can be sized to extend across one or more nodes of the track system. Larger sized track sections 132 would mean that fewer track sections 132 are required to make up, i.e., assemble, the track system 84. The distal ends 162 of one or more of the track section elements 134, 136 of adjacent track sections extend to meet in the region between the nodes of the track system 84 because this is an area of ​​the track system where the underlying track support structure 156 is less likely to be subject to any vertical displacement. In all cases, each track section 164, 166, 168 is a single, integral body having transversely extending portions or elements 134, 136 to provide a track surface or path for load handling devices to travel on the transversely extending track system. A single-molded track section with a transversely extending track surface or path significantly reduces the complexity and components required to assemble a grid framework structure in accordance with the present invention. A variety of materials can be used to fabricate the track sections. These include various metals, such as aluminum, plastics, such as nylon, and / or composite materials.

[0122] While the use of plastic materials offers advantages in terms of their moldability to tight dimensional tolerances, one of the drawbacks of using plastic materials is their inability to conduct static electricity accumulated on the surface of the track to ground as a result of the engagement of the wheels (primarily formed from non-conductive materials) of the load-handling device, particularly the tires on the wheels. To overcome this drawback, in certain embodiments of the present invention, the plastic material is made conductive by incorporating or mixing in a conductive material such that the track section is formed from a composite material. For example, a conductive filler can be mixed with the plastic material prior to molding to make the plastic material conductive. Examples of known conductive fillers include, but are not limited to, carbon (e.g., graphite) and metal fillers such as copper, silver, iron, etc. The conductive filler can be in particulate or fibrous form. For example, a conductive filler in the range of 20% to 50% by weight can be added to the plastic material to make it conductive. Alternatively, a conductor can be insert molded into the plastic material to provide a continuous conductive path through the track.

[0123] To secure multiple tracks to a track support structure, each of the track sections 132 can be snap-fit ​​to the track support structure. In a specific embodiment of the invention, the underside of the track section 132 shown in FIG. 33 includes one or more protrusions or tabs 170 configured to snap-fit ​​to the track supports 156 a, 156 b. The one or more protrusions 170 can include beads or protruding edges 172 configured to flex and received into one or more openings 174 in the opposing side walls (or vertical elements) of the track supports 156 a, 156 b in a snap-fit ​​configuration, as shown in FIGS. 30 and 31 . The specific snap-fit ​​feature shown in FIGS. 30 and 31 is a cantilever snap-fit. However, other forms of snap-fit ​​connections commonly known in the art for securing track sections to track supports are applicable to the present invention. Similarly, other forms of securing track sections to track supports other than snap-fit ​​joints, such as the use of fasteners or adhesives, are applicable to the present invention.

[0124] In addition to the thermal expansion of the different components of the support framework structure 82 and the track support structure 156 discussed above, one or more of the tracks 122a, 122b also experience thermal expansion in different temperature environments. This is particularly true when the tracks are separately mounted to the track support structure. If the tracks are made of a plastic material and the track support structure is primarily made of metal, there will be a thermal expansion coefficient mismatch between the tracks and the underlying track support structure 156 to the extent that thermal expansion results in differential movement between the two components. Because each of the track sections 132 includes track section elements 134, 136 that extend in a substantially transverse direction, relative movement between one or more of the track section elements and the underlying track support structure is largely concentrated in areas around the track section elements 134, 136 that extend from nodes in the track section 132. A node in a track section is an area where the track section elements in a given track section intersect. When the tracks are rigidly secured to the underlying track support structure, differential movement between one or more of the tracks and the underlying track supports 156a, 156b as a result of differential thermal expansion between the tracks and the track supports can distort one or more of the tracks. For example, if the underlying track support experiences greater thermal expansion than the tracks, forces resulting from the thermal expansion of the track support can tend to affect the connection between the tracks and the track support. In the worst case, differential thermal expansion between the tracks and the track support can result in failure of the connection between the tracks and the track support, and in the worst case, can lead to delamination or detachment of one or more of the tracks from the track support. When the track sections 132 are snap-fitted to the track support structure 156, failure of the connection between one or more of the tracks and one or more of the underlying track supports occurs primarily at the snap-fit ​​joint between the tracks and the track support structure.

[0125] To mitigate relative movement between the plurality of tracks and the underlying track support structure as a result of thermal expansion, the connection between each of the track sections and the underlying track support comprises a thermal expansion joint comprising a slip joint or a movement joint. If the connection between each of the plurality of track sections and the underlying track support structure comprises a snap-fit ​​joint, the snap-fit ​​joint between the track section and the track support is configured such that the connection allows one or more of the track section elements to expand or contract along a substantially horizontal direction relative to the underlying track support, i.e., along a plane in which the track system lies, but prevents movement in a substantially vertical direction to prevent the track section from detaching from the underlying track support. To accommodate the thermal expansion joint within the snap-fit ​​joint, one or more openings 174 in opposing sidewalls of the track support are enlarged in one or more directions to allow movement of the protrusions or tabs 170 within the one or more openings 174 in the track support. In a particular embodiment of the invention, as shown in FIG. 31 , each of the one or more openings 174 comprises a slot in an opposing sidewall of the track support, the slot being oriented so that its longest edge (i.e., slot length) extends along the longitudinal length of the underlying track support and its shortest edge (i.e., slot width) extends in a direction substantially perpendicular to the longitudinal length of the underlying track support. The slot is oriented such that a protrusion or tab 170 engaged with the slot 174 allows the protrusion or tab to move longitudinally along the slot, which in turn allows the track section element 134, 136 attached thereto to expand or contract relative to the underlying track support. Similarly, expansion or contraction of the underlying track support as a result of thermal expansion may reasonably cause the slot to move relative to the protrusion or tab 170 engaged therein. Various other means for incorporating a slip or movement joint into the connection between one or more of the plurality of tracks and the underlying track support structure are permissible in the present invention.For example, the connection between each of the plurality of tracks and the underlying track support structure can include one or more runners, e.g., telescoping drawer runners. Another means for providing one or more slip joints in the connection between each of the plurality of track sections, particularly the track section elements of the track sections, includes replacing one or more slots in opposing side walls of the track support with recesses extending along the longitudinal length of the track support and configured to cooperate in a slip-fit ​​arrangement with protrusions or tabs on the track. Similar to the one or more slots, one or more tabs or protrusions on the track section are configured to snap-fit ​​with the recesses.

[0126] The distal ends 162 of the track section elements of adjacent track sections are spaced apart to provide spacing for thermal expansion of one or more of the track sections in the track system. This spacing is sufficient to allow the track elements of adjacent track sections to expand on the underlying track support so that their respective distal ends 162 can connect or abut without buckling. This spacing also depends on the diameter of the wheels of a robotic load handling device operable on the track system. If the spacing between the distal ends of adjacent track elements is too large compared to the diameter of the wheels, this has the effect of introducing a step between the adjacent track section elements, causing the wheels of the robotic load handling device to get caught on or collide with the ends of the track section elements, and in the worst case, cause the wheels to sink or fall into the gap created by the spacing between the adjacent track section elements. This spacing should be sufficient to allow the wheels of the robotic load handling device to traverse the gap created by the spacing between the distal ends 162 of adjacent track sections 132 without excessive wheel snagging, but not so large that the wheels sink or fall into the gap. In certain embodiments of the present invention, the spacing between the distal ends 162 of adjacent track elements of adjacent track sections in a track system provides a gap 176 that contrasts with the spacing between adjacent vertical uprights of adjacent prefabricated frames in a supporting framework structure, i.e., the spacing is in the range of 0.5 mm to 5 mm, preferably 1 mm to 3 mm, and more preferably 1.5 mm to 3 mm. The spacing between the distal ends of the track elements is significantly affected by the thermal expansion of one or more prefabricated frames of the supporting framework structure. Typically, for wheels having a diameter of approximately 120 mm, the spacing can be up to 6 mm without the wheels excessively binding or sinking in the gap.

[0127] The track section elements of the track section are configured as a double track as shown in FIG. 32 , with two ridges or recesses 155 running side by side along the longitudinal length of each track section element 134, 136 for receiving and guiding the wheels of a robotic load handling device, and a central ridge 154 running parallel to the two ridges or recesses 155. Recesses 155 on either side of the central ridge 154 provide paths for engagement by the wheels of the robotic load handling device. Each track section element 134, 136 for guiding the wheels of the robotic load handling device includes two lips 152, one on each side of the wheel. In the case of a double track, there are two pairs of lips 152 running side by side along the longitudinal length of the track to guide the two pairs of wheels. This is to ensure that two load handling devices can pass each other in the X and Y directions when traveling on the double track in different directions on the same track section. To allow one or more load handling devices to pass each other at intersections or intersections of track sections corresponding to nodes in the track system, i.e., crossroads, the track intersections or intersections include small islands 178, as shown in FIG. 32, to allow wheels to be guided laterally. This is particularly the case in areas where tracks meet or intersect, which are primarily present around the central section of the track system. The track system of the present invention is not limited to dual tracks; a track element may consist of a single track with a single ridge or depression formed from a pair of lips on either side of the track to guide a single wheel along the track.

[0128] One or more guardrails 180 may optionally surround at least a portion of the perimeter of the track system 84 to prevent one or more robotic load handling devices operable on the track system from overrunning the track system. To maintain the modularity of the grid framework structure and its ability to be flat-packed, the guardrails 180 may also be modularized. The guardrails 180 are formed as prefabricated frames or panels having a lower portion 182 for mounting to the supporting framework structure 82 and an upper portion 184 that extends above the track system to form a barrier when mounted to the supporting framework structure. The prefabricated frames are different from the prefabricated frames for building the supporting framework structure discussed above. To distinguish them from the prefabricated frames of the supporting framework structure, the prefabricated frames forming the guardrails will be referred to as guardrail panels. Due to the weight of the robotic load handling devices, which may exceed 100 kg, and because the supporting framework structure is load-bearing, the guardrail panels are mounted to and supported by the supporting framework structure. As shown in FIG. 40 , the lower portion 182 includes vertical members that extend downward to connect to the vertical uprights of the supporting framework structure, and the upper portion 184 includes one or more horizontal members that brace the vertical members. Various fasteners known in the art may be used to secure the protective panels to the vertical uprights to the supporting framework structure, including, but not limited to, bolts, screws, etc. Optionally, brackets or clamps may be used to secure the protective panels to the supporting framework structure. Multiple protective panels are secured around the perimeter of the track system, so that each protective panel extends above the track system to form a protective enclosure or barrier around the perimeter of the track system.

[0129] One or more exterior walls of the supporting framework structure 82 may be clad with one or more solid wall panels 186, as shown in FIG. 41 , to encase the interior space of the supporting framework structure. The one or more solid walls 186 may be insulated to provide a thermal barrier to prevent heat from escaping from the interior space of the supporting framework structure 82. When the contents of a storage container are temperature sensitive, such as food items, the insulating cladding 186 encasing the exterior walls of the supporting framework structure 82 has the advantage of preventing heat transfer between the interior and exterior of the supporting framework structure 82. For example, the interior space of the supporting framework structure 82 may be a refrigerated zone operating within a temperature range of substantially 0° C. to substantially 5° C., or a freezer zone operating within a temperature range of substantially −25° C. to substantially 0° C., preferably substantially −21° C. to substantially −18° C. The exterior walls of the supporting framework structure may also be clad to improve the aesthetic appearance of the supporting framework structure.

[0130] When one or more load handling devices are operable on a track system, it is paramount that the track system be in a substantially horizontal plane, as this affects the direction in which storage containers or storage receptacles are lifted into position through the grid cells. If the level of the track system deviates from the horizontal plane, this not only places strain on one or more robotic load handling devices moving on the track system, but, depending on the direction of the deviation, may also cause the lifting tethers to tilt to one side, and in a worst-case scenario, cause the grabber devices to not engage with the container or storage receptacle below. This problem is exacerbated when the floor on which the grid framework structure is installed is uneven. One or more of the prefabricated braced frame and / or guide uprights may be mounted on an adjustable grid leveling mechanism (not shown) to adjust the level of the track system. The level of a track system mounted on the uprights is adjusted by having adjustable leveling feet at the base or bottom of the vertical uprights and / or the tote guides to compensate for uneven floors. The level of the track system is adjusted by adjusting adjustable leveling feet at the bases of one or more vertical uprights and / or tote guides in the grid framework structure and checking the level of the track system at the top of the grid framework structure after each adjustment is made, for example, by using a suitable leveling measuring tool such as a laser level commonly known in the art.

[0131] Assembly of a grid framework structure according to the present invention involves erecting a plurality of prefabricated frames in a grid pattern comprising a plurality of modular storage cells, each of which provides storage space for storing a plurality of stacks of storage containers. The prefabricated frames may be prefabricated on-site or at a remote location, transported to the site, and assembled into the supporting framework structure. For example, prefabrication may involve bracing a plurality of vertical uprights with one or more bracing members on-site. Prefabrication of the frames may be performed manually or automatically. A lifting device may be used to orient and position the prefabricated frames together. The lifting device may be operated manually or automatically. Figures 42(a and b) show an example in which an AGV (automated guided vehicle) 188 includes a tool or gimbal 190 specially adapted to engage with a prefabricated frame 86a, b and orient it for assembly into the supporting framework structure 82 according to the present invention. A gimbal 190 is defined as a pivoted support that allows rotation of an object about an axis. The gimbal 190, as shown in FIG. 42a, is connected to a lifting mechanism via a lifting arm 192 to allow the prefabricated frame 86a, b to be lifted into a position where it can be secured to an existing prefabricated frame in a supporting framework structure. A support surface 194 with one leg mounted thereon, as shown in FIG. 42a, can be used to provide the prefabricated frame with a gimbal for the lifting device. The support surface 194 can be equipped with a specially designed jig (not shown) to facilitate prefabrication of the frame. For example, in the case of a prefabricated braced frame, a specially designed jig can be used to properly align the uprights before they are braced by one or more bracing members.

[0132] Once the prefabricated frame is engaged with the gimbal, the lifting mechanism can lift the prefabricated frame off the support surface 194, allowing the AGV to be driven to the desired location on the jobsite. The gimbal allows the prefabricated frame to be oriented for assembly onto adjacent prefabricated panels. Multiple AGVs can be controlled by a control system to organize assemblies of multiple prefabricated frames into a supporting framework structure. Connecting adjacent prefabricated frames generally involves the use of several fasteners, including, but not limited to, one or more bolts, welds, rivets, or adhesives. Fastening the prefabricated frames together can be done manually or automatically when the prefabricated frame is provided to one of the other prefabricated frames in the supporting framework structure.

[0133] In addition to assembling the prefabricated frames together, one or more AGVs may be used to assemble prefabricated modular subframes together to form the track support structure. The individual prefabricated modular subframes may be secured into modular units by one or more fasteners, such as bolts, rivets, welding, or adhesives. Once the track support structures 156 are assembled together, multiple track sections may then be fitted to the track support structures to complete the track system of the grid framework structure. Because the individual track sections include snap-fit ​​features as discussed above, the individual track sections can be snapped together at the nodes of the track support structure to form the track system. The cross sections of the individual track sections help to mask any imperfections underlying the track support structure, especially at the nodes where the track supports intersect in the track support structure. In contrast to assembling grid framework structures known in the art, in which individual uprights are erected first and the top ends of the uprights are interconnected together by orthogonally extending vertical uprights, prefabrication of the components of the grid framework structure prior to assembly significantly reduces the time to erect the grid framework structure. Other advantages include ensuring that grid cells are uniformly sized throughout the track system, since portions of the track support structure are prefabricated prior to assembly, reducing the need for in-situ track support adjustments. Specially designed fixtures can be used to prefabricate the modular subframes to ensure that individual grid cells are "squared" and / or precisely aligned prior to installation on the support framework structure.

[0134] To access the contents of the storage containers, the majority of the grid columns are storage columns, i.e., grid columns in which storage containers are stored in stacks. However, the grid framework structure typically has at least one grid column that is not used to store storage containers but comprises a location or grid cell 42 where a cargo handling device can drop off and / or pick up the storage container so that the storage container can be transported to a second location (not shown in the prior art figures) where the storage container can be accessed from outside the grid or transferred from or into the grid. Within the art, such a location or grid cell is typically referred to as a "port," and the grid column in which the port is located can be referred to as a "delivery column" 196 (see FIG. 43d). The storage grid comprises two delivery columns. The first distribution column may, for example, include a dedicated drop-off port 198 at which a container handling vehicle can drop off a storage container to be transported through the distribution column and further to an access station or transfer station, and the second distribution column may include a dedicated pickup port 200 at which a container handling vehicle can pick up a storage container that has been transported through the distribution column from the access station or transfer station. Storage containers are fed into the access station and exit the access station via the first and second distribution columns, respectively (see FIG. 43a).

[0135] Upon receiving a customer order, a load handling device operable to travel on a track is instructed to pick up a storage container containing the ordered items from a stack in the grid framework structure and transport the storage container via a delivery column to a pick station 202, where the items can be removed from the storage container shortly thereafter. Typically, the load handling device transports the storage container or container to a container lifting device integrated into the grid framework structure. A mechanism of the container lifting device lowers the storage container or container to the pick station 202. At the pick station, the items are removed from the storage container. Picking can be performed robotically as taught in GB2524383 (Ocado Innovation Limited) or manually. After removal from the storage container, the storage container is transported to a second container lifting device, where it is lifted to grid level to a pickup port for removal by the load handling device and transported back to its location within the grid framework structure.

[0136] Separate areas are provided adjacent the storage columns to accommodate access stations for load handling devices to drop off or pick up storage containers to or from the pick stations 202. Typically, the separate areas are provided by incorporating mezzanine floors 204 supported by vertical beams between adjacent grid framework structures. The mezzanine floors provide separate areas for accommodating one or more service stations, such as one or more pick stations. Typically, the separate areas are tunnels with grid framework structures on either side of the tunnel. A track system from the adjacent grid framework structures extends across the top of the mezzanine floors to connect to track systems on either side of the mezzanine floor 204 such that the track system is in a substantially horizontal plane. One or more delivery and / or pickup ports are assigned to one or more grid cells of the track system extending across the mezzanine floors such that load handling devices operable on the track system can drop off or pick up storage containers to or from the pick stations below. As a result of the track system extending across the mezzanine, the supporting framework structure 212 at the top of the mezzanine tends to be shallower than the supporting framework structures 210 on either side of the mezzanine, i.e., it can accommodate only one or two layers of containers in a stack. Typically, the mezzanine is a continuous structure extending the length of the track system 84 supported by vertical beams. The vertical beams supporting the mezzanine abut against a grid framework structure on either side of the mezzanine. In addition to one or more pick stations 202, the separate area created by the mezzanine can also accommodate various other stations, including, but not limited to, a charging station for charging rechargeable batteries that power the load handling devices on the grid, and a service station for performing periodic maintenance on the load handling devices.However, a problem with continuous structures is that there is little flexibility to expand the mezzanine and the surrounding grid framework structure without having to replace the mezzanine. Typically, the mezzanine is first erected as a continuous structure, and the grid framework structure is then assembled around the mezzanine. The shape and footprint of the grid framework structure are greatly influenced by the shape and footprint of the mezzanine. Because the shape or footprint of the mezzanine is fixed, the process of assembling the grid framework structure around the mezzanine does not lend itself to having the flexibility to expand the storage capacity of the grid framework structure, as it would result in the mezzanine needing to be redesigned to accommodate additional storage columns.

[0137] In contrast to continuous construction, a mezzanine floor 204 according to the present invention can employ modular construction, as shown in Figures 43(a-d). The modularity of the mezzanine floor 204 allows it to be assembled in sections 205, as shown in Figure 43c, to accommodate increasing service requirements of the grid framework structure 80. This allows the mezzanine floor 204 to be constructed in separate sections 205 in parallel with the grid framework structure, thereby increasing the footprint of the grid framework structure and providing increased storage capacity. In the specific embodiment of the present invention shown in Figure 43c, the mezzanine floor is constructed from separate, individual sections 205, eliminating the need to size the mezzanine floor prior to assembling the grid framework structure. Because the grid framework structure of the present invention is modular, the mezzanine floor can be easily coupled to the grid framework structure and can be constructed in parallel with the assembly of the grid framework structure. The modularity of the mezzanine floor means that grid framework structures of different sizes and shapes can be assembled to couple with the mezzanine floor.

[0138]

[00107] Erection of the supporting framework structure involves assembling and combining a plurality of individual modular blocks or units, i.e., first, second, and third type modular units 116, 118, 120, into a plurality of modular units extending across the mezzanine floor (see Figure 43b). As shown in Figure 43b, the supporting framework structure comprises a first region 210 and a second region 212. The first region 210 of the supporting framework structure surrounds the mezzanine floor 204, and the second region 212 of the supporting framework structure extends across the mezzanine floor 204. As shown in Figure 43b, the first region of the supporting framework structure is at a different height from the second region 212 of the supporting framework structure, which extends across the mezzanine floor 204, such that the track system extending across the first and second regions of the supporting framework structure lies in a substantially horizontal plane. As a result, the modular units comprising the first region 210 of the support framework have a different height than the modular units comprising the second region 212 of the support framework structure to correspond to the height of the mezzanine. FIG. 43d is an isometric view of the second region of the support framework structure supported by the mezzanine in accordance with the present invention. Also shown in FIG. 43d are delivery columns 196 extending from the track system above the mezzanine to one or more pick stations 202 below the mezzanine. Each of the storage columns above the mezzanine has a storage capacity up to the height of two storage containers. To put this in perspective, typical storage containers have heights in the range of 350 mm to 400 mm.

[0139] In the example shown in Figures 43a and 43b, the first region 210 of the supporting framework structure 210 has storage capacity for storing multiple stacks of storage containers, each stack of storage containers being capable of holding a height of up to 21 storage containers. Similarly, the second region 212 of the supporting framework structure 212 has storage capacity for storing multiple stacks of storage containers, each stack of storage containers being capable of holding a height of up to two storage containers. The modularity of the mezzanine 204 discussed above allows it to accommodate supporting framework structures of different sizes and shapes. For example, as shown in Figures 43a and 43b, the storage capacity of the grid framework structure can be easily increased by connecting additional modular units to the existing grid framework structure. The modularity of the mezzanine would mean that the mezzanine could be assembled in parallel with additional modular units of the supporting framework structure.

[0140] In addition to having first and second regions of the supporting framework structure, a track system extending across the supporting framework structure includes a first region 206 and a second region 208, where the first region 206 of the track system extends across the first region 210 of the supporting framework structure and the second region 208 of the track system extends across the second region 212 of the supporting framework structure. The first region 210 of the track system can be coupled to the second region 212 of the track system by one or more slip joints or movement joints as discussed above. The one or more slip joints coupling the first and second regions of the track system allow the first region 210 of the supporting framework structure to move independently of the second region 212 of the supporting framework structure. For example, during an earthquake event, ground movement will cause the supporting framework structure to vibrate. Because the first region 210 of the supporting framework structure is higher than the second region 212, the first region of the supporting framework structure will vibrate more than the second region 212 during ground movement. Without any independent movement between the first and second regions of the supporting framework structure, there is a risk that the first region of the supporting framework structure may apply excessive force to the second region of the supporting framework structure. In the worst case, the force may become excessive and cause structural damage to the supporting framework structure. One or more slip joints interposed between the first region 206 and the second region 208 of the track system allow the first region of the supporting framework structure to move independently of the second region of the supporting framework structure.

[0141] To incorporate one or more slip joints between the first and second regions of the track system, the interconnection of the plurality of track supports at the junction between the first and second regions of the track system comprises one or more slip joints. In certain embodiments of the invention, a junction zone 214 comprising a plurality of mating track supports connects the first and second regions of the track system (see FIG. 43c). The mating track supports connect the first and second regions of the track system by one or more slip joints or movement joints. The one or more slip joints or movement joints may be the same slip joints or movement joints as discussed above at the junction between modular storage cells. The mating track supports connecting the first and second regions of the track system can be seen in FIG. 44 and comprise a plurality of bridge elements 220 extending in a first direction or a second direction across the junction zone 214. Each of the plurality of bridge elements is configured to receive a single track element extending across the bridge element to allow a load handling device to move between the first and second regions of the track system. Similar to the track element discussed above with reference to Figure 30, a single track element may be mounted to the bridge element by a snap-fit ​​joint.

[0142] As an alternative to or in addition to one or more slip joints connecting the first and second regions of the track system, the connection between the first and second regions of the track system can include one or more mechanical fuses configured to break or shear under an applied load equal to or greater than a predetermined load, the predetermined load being lower than the load required to break the interconnections at the intersections of the track supports. This allows the first region of the track system to separate from the second region of the track system when the applied load exceeds the predetermined load. One or more mechanical fuses 222 connect the bridge element 220 to the first region 206 and the second region 208 of the track system. Because there is a separation between the first and second regions of the supporting framework structure, disconnection of the track system at the connection zone separates the grid framework structure around the mezzanine floor from the grid framework structure extending across the mezzanine floor. For purposes of defining this invention, the grid framework structure comprising the first region 206 of the track system and the first region 210 of the supporting framework structure is referred to as the first region 216 of the grid framework structure. Similarly, the grid framework structure comprising the second region 208 of the track system and the second region 212 of the support framework structure is referred to as the second region 218 of the grid framework structure. When excessive load is applied to the mechanical fuse, for example during a seismic event, the first region 216 of the grid framework structure is configured to disconnect from the second region 218 of the grid framework structure so that they can each move independently.

[0143] To allow the first region 210 of the grid framework structure to move independently of the second region 212 of the grid framework structure, there is also a separation L between the first and second regions of the supporting framework structure connected by the coupling zone 214 of the track system. The separation may be one or more grid cells of the track system. The vertical members 88 adjacent to the mezzanine floor 204 are spaced apart from the mezzanine floor such that movement of the vertical members 88 in the first region of the supporting framework structure does not affect movement of the mezzanine floor 204. The only connection between the first region of the supporting framework structure and the second region of the supporting framework structure is through the coupling zone or region 214 of the track system, and more specifically, the connection of the plurality of track supports in the coupling zone 214.

[0144] One or more mechanical fuses may be incorporated into one or more slip joints connecting the first and second regions of the track system. For example, referring to the slip joint shown in FIG. 24c, a pin 146f receivable in an opening 157 in the track support may be configured to break or shear when a laterally applied load exceeds a predetermined load. Alternatively, each of the plurality of bridge elements may be connected to the respective track supports in the first and second regions of the track system by one or more bolts having a break zone configured to shear when a predetermined load is applied. Typically, during a seismic event, the predetermined load has a load path in a horizontal plane. Ground movement as a result of a seismic event may cause the grid framework structure to vibrate in both the X and Y directions in the horizontal plane. To accommodate movement of the grid framework structure in both the X and Y directions, the mechanical fuses 222 may include sliding surfaces that face each other, as shown in FIG. 45. The opposing sliding surfaces are configured to slide relative to one another when an applied load exceeds a predetermined load, causing a first region of the grid framework structure to separate from a second region of the grid framework structure. The opposing sliding surfaces have a coefficient of friction such that the sliding surfaces slide relative to one another when the applied load exceeds the predetermined load. In extreme cases, the sliding surfaces may separate or "pop out" when the applied force exceeds the predetermined force. In both examples discussed above, bridge element 220 includes first and second portions 224a and 224b connected together by one or more slip-joint mechanical fuses, such that mechanical fuse 222 separates when the applied load exceeds the predetermined load.

[0145] A variety of materials may be used to make the components used in the prefabricated frame, prefabricated modular subframe, and / or track sections, including metals such as stainless steel, galvanized steel, aluminum, plastics, or fiber composites.

Claims

1. 1. A grid framework structure for supporting one or more robotic load handling devices operable thereon, the grid framework structure comprising: i) a supporting framework structure comprising a plurality of prefabricated frames arranged in a three-dimensional grid pattern comprising a plurality of modular storage cells for storing a plurality of stacks of containers such that adjacent modular storage cells share a common prefabricated frame, wherein each of said plurality of prefabricated frames comprises a plurality of vertical members lying in a vertical plane and braced by bracing members; ii) a track system for guiding movement of one or more of the robotic load handling devices on the grid framework structure, wherein the track system comprises a plurality of tracks mounted to the support framework structure and arranged in a grid pattern comprising a plurality of grid cells extending across a plurality of the modular storage cells, such that each of the plurality of modular storage cells supports a subgroup of two or more grid cells of the track system; the track system further comprising a track support structure comprising a plurality of track supports arranged in a grid pattern corresponding to the grid pattern of the track system, the plurality of track supports being interconnected at intersections of the plurality of track supports in the grid pattern, the track support structure being subdivided into a plurality of modular sub-frames, each modular sub-frame comprising a sub-group of two or more grid cells of the track system; the interconnection of the plurality of track supports at joints between adjacent modular storage cells comprises one or more slip joints such that adjacent modular subframes are movable relative to one another along a substantially horizontal plane via the one or more slip joints.

2. One or more of the slip joints may be i) a first set of slip joints at the connections between adjacent modular storage cells in the first direction such that adjacent modular sub-frames are movable relative to one another along the substantially horizontal plane in the first direction; ii) a second set of slip joints at the joints between adjacent modular storage cells in the second direction such that adjacent modular subframes are movable relative to one another along the substantially horizontal plane in the second direction; and 2. The grid framework structure of claim 1, wherein the second direction is substantially perpendicular to the first direction.

3. 3. The grid framework structure of claim 1 or 2, wherein the supporting framework structure is arranged such that one or more vertical members of adjacent prefabricated frames are connected together by one or more fasteners at the joints between adjacent modular storage cells.

4. The grid framework structure of claim 3 , wherein one or more spacers are disposed between adjacent said vertical members at the joints between adjacent modular storage cells.

5. 4. The grid framework structure of claim 3, wherein each of the one or more spacers comprises a first spacing member and a second spacing member, the first spacing member configured to separate adjacent vertical members connected in the first direction by a first spacing, and the second spacing member configured to separate adjacent vertical members connected in the second direction by a second spacing.

6. The grid framework structure of claim 5 , wherein the first spacing is different from the second spacing.

7. 7. The grid framework structure of claim 4, wherein the one or more spacers comprise a plurality of spacers distributed along the longitudinal lengths of adjacent vertical members at the joints between adjacent modular storage cells.

8. 8. The grid framework structure of any one of claims 1 to 7, wherein a plurality of the prefabricated frames are arranged to form a first type modular unit and a second type modular unit, the second type modular unit having a coupling portion configured to couple with the first type modular unit to form at least a portion of the supporting framework structure comprising at least two modular storage cells sharing at least one common prefabricated frame at the coupling between adjacent modular storage cells.

9. 9. The grid framework structure of claim 8, wherein the first type modular units are closed-sided modular units and the second type modular units are open-sided modular units having an open side along one side of the modular units, such that the open side of the second type modular units is configured to be closed by sharing the common prefabricated frame with the first type modular units.

10. 10. The grid framework structure of claim 9, wherein the first type of modular unit comprises four prefabricated frames arranged to form a closed-sided structure and the second type of modular unit comprises three prefabricated frames arranged to form a substantially U-shaped structure, the substantially U-shaped structure of the second type of modular unit being closed by sharing the common prefabricated frame with any one of the closed-sided structures of the first type of modular unit.

11. 11. A grid framework structure according to any one of claims 8 to 10, wherein the plurality of modular subframes of the track support structure comprise a first type modular subframe and a second type modular subframe, the first type modular subframe being a closed-sided subframe and the second type modular subframe being an open-sided subframe, the first type modular subframe being configured to be mounted to the first type modular unit and the second type modular subframe being configured to be mounted to the second type modular unit, such that the open-sided subframe of the second type modular subframe is closed by a side of the first type modular subframe at the joint between adjacent modular subframes comprising one or more of the slip joints.

12. 12. The grid framework structure according to any one of claims 8 to 11, wherein a plurality of the prefabricated frames are arranged to form a third type modular unit, the third type modular unit comprising at least two coupling portions configured to couple with the first, second and / or third modular units to form at least four modular storage cells.

13. 13. The grid framework structure of claim 12, wherein the third type modular units are open-sided modular units along two sides of the modular unit, such that the open-sided modular units along the two sides of the modular unit are configured to be closed by sharing two common prefabricated frames with the first and / or second type modular units between adjacent modular storage cells.

14. 14. A grid framework structure according to claim 12 or 13, wherein the third type of modular unit comprises two prefabricated frames arranged to form a substantially L-shaped structure.

15. 15. The grid framework structure of any one of claims 12 to 14, wherein the plurality of modular sub-frames of the track support structure further comprises a third type modular sub-frame, the third type modular sub-frame being an open-sided sub-frame along two sides of the modular sub-frame, configured to be installed on the third type modular units, such that the open-sided sub-frames of the third type modular sub-frame along the two sides of the modular sub-frame are configured to be closed by respective sides of the first type modular sub-frame and / or second type modular sub-frame between adjacent modular storage cells comprising one or more of the slip joints.

16. A grid framework structure according to any one of claims 12 to 15, wherein the first and / or second and / or third type modular units are stand-alone sub-structures.

17. 17. The grid framework structure of any one of claims 1 to 16, wherein each of the plurality of modular storage cells comprises a plurality of tote guides extending substantially vertically between the track system and a floor, the plurality of tote guides being arranged in a pattern to accommodate a stack of storage containers between the plurality of tote guides and to guide the storage containers through respective grid cells of the track system.

18. 20. The grid framework structure of claim 17, wherein each tote guide of the plurality of tote guides comprises two vertical tote guide plates extending longitudinally along the length of the tote guide.

19. A grid framework structure according to any preceding claim, wherein each of the prefabricated frames comprises an A-frame.

20. 20. The grid framework structure of claim 19, wherein a plurality of the vertical members of each of the prefabricated frames are braced by one or more horizontal and / or diagonal braces.

21. 21. The grid framework structure of claim 20, wherein the cross-sectional profile of each of a plurality of said vertical members in a given prefabricated frame is different from the cross-sectional profile of one or more of said horizontal and / or diagonal brace members.

22. 22. A grid framework structure according to claim 20 or 21, wherein each of one or more of the horizontal and / or diagonal bracing members is reinforced by one or more inserts.

23. A grid framework structure according to any preceding claim, wherein a plurality of the tracks are configured to be mounted to or integral with the track support structure.

24. 24. The grid framework structure of claim 23, wherein the plurality of tracks comprises a plurality of modular track sections, each modular track section of the plurality of modular track sections comprising a substantially vertical track section element to provide a vertically extending track surface.

25. 25. The grid framework structure of claim 24, wherein each of the plurality of modular track sections is formed as a one-piece, unitary body.

26. 26. A grid framework structure according to any one of claims 1 to 25, wherein one or more of the slip joints each comprise a limit stop for limiting relative movement between adjacent modular sub-frames over a predetermined distance along the substantially horizontal plane.

27. 1. A storage and retrieval system comprising: i) a grid framework structure according to any one of claims 1 to 26; ii) a plurality of stacks of containers disposed in storage columns located below the track system, wherein each storage column is located vertically below a grid cell; iii) a plurality of cargo handling devices for lifting and moving the stacked containers in said stack; a plurality of said cargo handling devices are remotely operated to move laterally on said track system above said storage columns to access said containers through said grid cells, and each of said plurality of said cargo handling devices comprises: a) a wheel assembly for guiding the load handling device on the track system; b) a container receiving space located above the track system; c) a lifting device arranged to lift a single container from the stack into said container receiving space; A storage and retrieval system comprising:

28. A method of assembling a grid framework structure according to any one of claims 1 to 26, comprising the steps of: i) assembling a plurality of prefabricated frames in a grid pattern to form a supporting framework structure comprising a plurality of modular storage cells, such that adjacent modular storage cells share a common prefabricated frame; ii) installing a plurality of said modular subframes in a substantially vertical orientation on said supporting framework structure such that said joints between adjacent modular subframes are interconnected by one or more said slip joints; A method comprising:

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