Storage and retrieval system

Abstract

The present invention provides an automated storage and retrieval system comprising at least one autonomous transport vehicle, a transport deck defining a transport surface for the vehicle, at least one reciprocating lift, and first and second pick-face interface stations connected to the deck and spaced apart from each other. [Solution] A pick face transfer is formed at each station that interacts between the vehicle on the deck and the lift so that a pick face is transferred between the lift and the vehicle at each station, and the vehicle is configured to take out a first pick face at the first station, move back and forth across the deck, and buffer the first pick face or at least a portion thereof at the second station so that the second station has a plurality of pick faces that are buffered at a common support in an order sequence of pick faces according to the unloading order sequence of a given case of pick faces of mixed cases.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is a non - provisional patent application of U.S. Provisional Patent Application No. 62 / 104,520, filed on January 16, 2015, claims the benefit of this application, and the disclosure content is incorporated herein by reference in its entirety.

[0002] This application is also related to U.S. Patent Application No. 14 / 966,978, filed on December 11, 2015; U.S. Patent Application No. 14 / 997,892, filed on January 18, 2016; U.S. Patent Application No. 14 / 997,902, filed on January 18, 2016; U.S. Patent Application No. 14 / 997,925, filed on January 18, 2016; and U.S. Provisional Patent Application No. 62 / 107,135, filed on January 23, 2015, the entire disclosure content of which is incorporated herein by reference.

[0003] [Technical Field] Exemplary embodiments generally relate to an article handling system, and more particularly, to the conveyance and storage of items within an article handling system.

Background Art

[0004] Multi-level storage and retrieval systems may be used in warehouses for the storage and retrieval of goods. Generally, the transport of goods in and out of the storage structure is carried out by lifts for transporting goods to vehicles on storage levels, vehicles moving up ramps to designated storage levels, or vehicles including lifts moving along guide paths. Goods stored within the storage and retrieval system are generally stored in storage spaces on each storage level, and transport vehicles positioned on those storage levels have access to one level of storage space. Generally, lifts that transport goods to and from storage spaces and transport vehicles between different storage levels are either integrated into the vehicle (e.g., by gantry cranes) or have a parternoster configuration in which the lift's loading racks continuously circulate around a frame at a predetermined speed.

[0005] Case units retrieved from a multi-level storage and retrieval system are transported to a packaging station where they are placed on pallets for delivery. Generally, pallets contain case units of similar size and shape, so a stable case level is formed on the pallet, sometimes with corrugated sheets between the levels. In some examples, each level of the pallet stack is formed separately and then placed on the pallet to form a stacked stack. Mixed pallets are also possible. Generally, when forming a pallet stack, cases are placed at a buffer station or elsewhere in the pallet loading station so that the dimensions of the cases can be measured. A computer or other processor determines the placement of the cases based on the dimensions and instructs a robot to retrieve the cases for placement on the pallet stack. [Overview of the Initiative]

[0006] To increase the processing capacity of the storage and retrieval system, it would be advantageous to classify the case units for placement on pallets during transport of the case units from the storage structure of the storage and retrieval system. [Brief explanation of the drawing]

[0007] The above-described aspects and other features of the disclosed embodiments are described in the following description in conjunction with the accompanying drawings.

[0008] [Figure 1] This is a schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1A] This is a schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1B] This is a partial schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1C] This is a partial schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1D] This is a partial schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1E] This is a partial schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1F] This is a schematic diagram of a mixed pallet load formed by an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1G] This is a partial schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2A] This is a partial schematic diagram of a storage and retrieval system according to an embodiment of the disclosed model. [Figure 2B] This is a partial schematic diagram of a storage and retrieval system according to an embodiment of the disclosed model. [Figure 3A] This is a partial schematic diagram of a storage and retrieval system according to an embodiment of the disclosed model. [Figure 3B] This is a partial schematic diagram of a storage and retrieval system according to an embodiment of the disclosed model. [Figure 4A] This is a partial schematic diagram of a storage and retrieval system according to an embodiment of the disclosed model. [Figure 4B]Partial schematic diagram of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 5] Partial schematic diagram of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 6] Schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 6A] Schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 7] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 8] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 9] Partial schematic diagram of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 10] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 10A] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 10B] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 10C] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 10D] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 10E] Partial schematic diagram of a transport vehicle according to an aspect of the disclosed embodiment. [Figure 11] Partial schematic diagram of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 12] Partial schematic diagram of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 13] Partial schematic diagram of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 14] Exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 15]An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 16] An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 17] An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 18] An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 19] An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 20] An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 21] A partial schematic view of an automatic storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 22A] A partial schematic view of an automatic storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 22B] A partial schematic view of an automatic storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 23] An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 24] A partial schematic view of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 25] An exemplary flowchart according to an aspect of the disclosed embodiment. [Figure 26] A schematic view of an operator station of a storage and retrieval system according to an aspect of the disclosed embodiment. [Figure 27] An exemplary flowchart according to an aspect of the disclosed embodiment.

Mode for Carrying Out the Invention

[0009] Figure 1 is a schematic diagram of the automated storage and retrieval system 100 according to an embodiment of the disclosed embodiment. While the embodiments of the disclosed embodiment are described with reference to the drawings, it should be understood that the embodiments of the disclosed embodiment can be embodied in many forms. In addition, elements or materials of any appropriate size, shape, or type may be used.

[0010] In some embodiments of the disclosed features, the automated storage and retrieval system 100 may operate in a retail distribution center or warehouse to fulfill orders for case units, such as those described in U.S. Patent Application No. 13 / 326,674, filed December 15, 2011, which are entirely incorporated herein by reference, received from retailers. For example, a case unit is a case or unit of goods that are not stored (e.g., not contained) in trays, on totes or on pallets. In other examples, a case unit is a case or unit of goods that are contained in any suitable way, such as in trays, on totes or on pallets. In yet another example, a case unit is a combination of goods that are not contained and goods that are contained. Note that a case unit may include, for example, a unit of goods in a box (e.g., a case of soup cans, a box of cereal, etc.) or individual goods that are adapted to be retrieved from or placed on a pallet. In accordance with aspects of the disclosed embodiments, the delivery cases for the case units (e.g., cartons, barrels, boxes, crates, jugs, or any other device suitable for holding the case units) may be variable in size, may be used to hold the case units in delivery, and may be configured to be loadable onto pallets for delivery. Note that, for example, when a group of case units or pallets arrive at a storage and retrieval system, the contents of each pallet may be identical (e.g., each pallet holds a predetermined number of identical items—one pallet holds soup and another holds cereal), and when the pallets leave the storage and retrieval system, the pallets may contain a suitable number and combination of different case units that are supplied to a palletizer, for example, in a sorted arrangement to form a mixed pallet (e.g., a mixed pallet, where each mixed pallet holds different types of case units—one pallet holds a combination of soup and cereal).In embodiments, the storage and retrieval systems described herein may be applied to any environment in which the case units are stored and retrieved.

[0011] Referring also to Figure 1F, it should be noted that, for example, when a batch or pallet arriving (e.g., from a manufacturer or wholesaler of case units) arrives at the storage and retrieval system 100 for replenishment, the contents of each pallet may be identical (for example, each pallet may hold a predetermined number of identical items—one pallet holding soup, another pallet holding cereal). As can be understood, the cases of such pallet loads may be substantially similar, in other words, they may be of the same type (e.g., similar dimensions) and may have the same SKU (or, as mentioned above, the pallet may be a "rainbow" pallet with layers formed of cases of the same type). When the pallet PAL leaves the storage and retrieval system 100 with the cases fulfilled, the pallet PAL may contain any appropriate number and combination of different case units CU (for example, each pallet may hold different types of case units—one pallet may hold a combination of canned soup, cereal, beverage packs, cosmetics, and household detergents). Cases assembled on a single pallet may have different dimensions and / or different SKUs. In one embodiment of an exemplary configuration, the storage and retrieval system 100 may generally be configured to include an incoming section, a storage and sorting section (in one embodiment, storage of goods is optional), and an outgoing section, as will be further detailed below. To be understood, in one embodiment of the disclosed configuration, the system 100, operating, for example, as a retail distribution center, may function to receive cases of a single pallet load, disassemble the goods on the pallet from the single pallet load into independent case units operated individually by the system, or to detach the cases, retrieve different cases required by each order and sort them into corresponding groups, transport the corresponding groups of cases, and assemble them into what may be called a mixed case pallet load (MPL).As can be understood, as shown in Figure 26, in one embodiment of the disclosed embodiments, a system 100 operating as, for example, a retail distribution center may receive a case of a single pallet load, disassemble the goods on the pallet from the single pallet load into independent case units operated individually by the system, or separate the cases, take out different cases required by each order and sort them into corresponding groups, transport the corresponding groups of cases, and order the corresponding groups of cases at an operator station 160EP (as described herein), where the goods taken out from different case units CU and / or the different case units CU themselves are placed by operator 1500 or any appropriate automation into one or more bags, totes or other suitable containers TOT in a predetermined order sequence of goods taken out, for example, in accordance with an order to fulfill an order of one or more customers, in which case the case units CU are ordered at operator station 160EP according to a predetermined order sequence, and it should be noted that the ordering of case units CU as described herein results in the ordering of case units CU at operator station 160EP. The receiving section may generally be able to disassemble a single pallet load into individual cases, and the cases may be able to be transported via a suitable transport unit for delivery to the storage and sorting sections. In other embodiments, the unloading section assembles a suitable group of ordered case units, which may differ in SKU, dimensions, etc. (for example, to fulfill a customer order), into bags, totes, or other suitable containers according to a predetermined order sequence of items to be retrieved.

[0012] The storage and sorting section includes a multi-level automated storage array having a transport system for receiving individual cases one after another for storage in a storage area and supplying individual cases into a multi-level storage array, as will be further detailed below. The storage and sorting section also defines the outbound transport of case units from the multi-level storage array so that desired case units are individually retrieved according to instructions generated in response to orders entered into a warehouse management system, such as warehouse management system 2500, for transport to the outbound section. In other embodiments, the storage and sorting section receives individual cases, sorts the individual cases (for example, using buffers and interface stations as described herein), and transports the individual cases to the outbound section according to orders entered into the warehouse management system. The sorting and grouping of cases according to orders (e.g., order outbound sequences) may be carried out in whole or in part by either the storage and retrieval section or the outbound section, or both, with the boundary between them being one for convenience of explanation, and sorting and grouping can be carried out in numerous ways. The intended result is for the unloading section to assemble a suitable group of ordered cases, which may differ in SKU, dimensions, etc., into a mixed case pallet load in the manner described, for example, in U.S. Patent Application No. 13 / 654,293 (now U.S. Patent No. 8,965,559), filed October 17, 2012, the entirety of which is incorporated herein by reference.

[0013] In exemplary embodiments, the unloading section may be referred to as a structured structure of mixed case stacks, which generates a pallet load. The structured structure of pallet loads described herein is representative, and in other embodiments, pallet loads may have any other suitable configuration. For example, the structured structure may be any suitable predetermined configuration, such as a truck load or other suitable container, or a load container frame for holding a structural load. The structured structure of pallet loads may also be characterized as having several flat case layers L121-L125, L12T, at least one of which is formed from a non-intersecting, self-supporting, and stable stack of mixed cases. The stacks of mixed cases in a given layer may have substantially the same height to form the top and bottom surfaces of the given layer such that they can be perceived as substantially flat, and there may be a sufficient number to cover the pallet area or a desired portion of the pallet area. The layers placed on top may be oriented such that the cases of the corresponding layer straddle the stacks of the supporting layer. Thus, the stacks are stabilized, and the boundary layers of the pallet load are stabilized accordingly. When defining palletized loads into a structured layered configuration, the interconnected 3-D palletized load solution is broken down into two parts that can be stored separately: a vertical (1-D) portion that breaks down the load into layers, and a horizontal (2-D) portion that efficiently distributes stacks of equal height to fill the pallet height of each layer. As described later, the storage and retrieval system delivers the case units to the unloading section so that the two parts of the 3D palletized load solution are broken down. A predetermined configuration of mixed palletized loads determines the order of the case units and whether the case units provided to the load construction system by the sorting and unloading section (which may be automated or manually loaded) are pick faces of single case units or pick faces of combined case units.

[0014] Referring again to Figure 1, according to an aspect of the disclosed embodiment, the automated storage and retrieval system 100 includes an inbound station 160IN (including a depalletizer 160PA and / or conveyor 160CA for transporting items to a lift module for entry into the storage area), an outbound station 160UT (including a palletizer 160PB, operator station 160EP, and / or conveyor 160CB for transporting case units from the lift module for removal from the storage area), inbound and outbound vertical lift modules 150A, 150B (generally referred to as lift module 150; although inbound and outbound lift modules are shown, a single lift module may be used for both transporting case units into and out of the storage structure), a storage structure 130, and a number of unmanned rovers or transport vehicles 110 (hereinafter referred to as "bots"). It should be noted that the depalletizer 160PA may be configured to remove case units from pallets so that the receiving station 160IN can transport the goods to the lift module 150 for loading into the storage structure 130. The palletizer 160PB may be configured to place the goods removed from the storage structure 130 onto a pallet PAL (Figure 1F) for delivery. As used herein, the lift module 150, the storage structure 130, and the bot 110 may collectively be referred to herein as the multi-level automated storage array (e.g., storage and sorting section) described above, which provides a three-dimensional multi-level automated storage array in which each processing axis has integrated "on-the-fly" sorting (e.g., sorting of case units in transit) so that the sorting and processing of case units occur substantially simultaneously without the need for a dedicated sorter, which is described in more detail below, for defining the transport / processing axes (e.g., three-dimensional) (e.g., with respect to the reference coordinate system REF of the bot 110 (Figure 6), or any other suitable storage and retrieval system).Since classification along each processing axis is selectable, the unloading of the load (e.g., the transfer of case units to form palletized loads) can occur along all processing axes, or along any combination of multiple / one processing axes without any substantial processing cost for processing case units that do not involve classification at all (e.g., "unclassified" processing). As an example of processing case units with respect to classification, also refer to Figure 1A, the storage and retrieval system 100 includes several processing areas or processing regions. For example, there are processes at the unloading station 160TP, which include: storage of multi-level case units 130LTP (e.g., placing case units into the storage area); transport of horizontal case units 110TP (e.g., transporting case units from the storage area along the retrieval passage and transport deck); buffering of case units BTSTP (e.g., buffering of case units to facilitate transport of case units between the storage area and the vertical transport area); vertical transport process 150TP (e.g., transport of case units by vertical lift); and transport by conveyor 160CB and palletizing by palletizer 160PB. In one embodiment, the classification of the case units described herein is brought about substantially simultaneously (e.g., "on the fly") with the processing 130LTP, 110TP, BTSTP, 150TP of the case units along each processing axis (e.g., the X, Y, and Z axes with respect to the reference coordinate system of the bot 110 and / or lift 150), and the classification along each axis is independently selectable so that the classification is brought about along one or more X, Y, and Z axes.

[0015] As can be understood, on-the-fly sorting of case units occurs, in one aspect, on the bot 110 without unloading the case units / pick faces being carried by the bot 110, whether the bot 110 is moving between case unit / pick face holding positions or is static / immobile (e.g., not moving between transport decks, retrieval aisles, etc.). As will be described later, one or more of the high-density multi-level shelf aisles, the linear buffer stations BS along the transport deck 130B, and the linear multi-location transport stations TS result in on-the-fly sorting substantially concurrent with processing along the X-axis. As will be described later, one or more of the transfer arm and end effector 110PA of the bot 110 (the transfer arm and end effector 110PA of the bot 110 are configured to sort cases / pick faces through the movement of the end effector along the Y-axis for multiple independent retrieval / placement of cases / pick faces, the Y-axis being defined by the extension of the transfer arm 110PA and in another direction angled to another of the transport axes defined by the bot 110 along the retrieval passage 130A), as well as the independent load processing device of the lift 150 (configured for sorting on the lift platform through the extension of the load processing device along the Y-axis), result in on-the-fly sorting substantially concurrent with the processing along the Y-axis. As can be understood, the lift 150 is configured to transport pick faces between different transport deck levels and provide on-the-fly sorting substantially concurrent with the processing along the Z-axis (defined by the lift 150), as described herein. In one embodiment, the lift is configured to pick up one or more pick faces from one or more transfer deck levels and transport these one or more pick faces to a load-filling section or cell (such as an unloading station 160UT) of the storage and retrieval system 100.A load filling section or load filling cell (as used herein, and generally referred to as a load filling unit) refers to either a pallet load filling section / cell (for example, for the production of mixed pallet loads MPL) or a load filling section / cell for each item, as described with respect to Figure 26.

[0016] Referring also to Figures 1G and 2A, the storage structure 130 may include multiple storage rack modules RM, which consist of a high-density three-dimensional rack array RMA accessible from the storage or deck level 130L. As used herein, the term “high-density three-dimensional rack array” means a three-dimensional rack array RMA having non-deterministic open shelves distributed along the retrieval passage 130A, where the stacked shelves are accessible from the moving plane or retrieval passage level of a common retrieval passage (for example, as further detailed below, the case units are positioned at each retrieval passage level within the dynamically allocated storage space such that the vertical space / gap VG and horizontal space / gap G between case units are minimized at each retrieval passage level).

[0017] Each storage level 130L includes a pick-face storage / transfer space 130S (hereinafter referred to as storage space 130S) formed by rack modules RM, the rack modules including shelves arranged along a storage or retrieval passage 130A (connected to the transport deck 130B) that extends linearly through, for example, a rack module array RMA and provides access for bots 110 to the storage space 130S and the transport deck 130B. In one embodiment, the shelves of the rack module RM are arranged as multi-level shelves distributed along the retrieval passage 130A. As can be understood, in order to transport case units between any of the storage spaces 130S of the storage structure 130 (for example, on the level where bots 110 are located) and any of the lift modules 150, bots 110 move along the retrieval passage 130A and the transport deck 130B on their respective storage levels 130L (for example, each bot 110 has access to each storage space 130S on its respective level and each lift module 150 on its respective storage level 130L). The transfer decks 130B may be stacked vertically or horizontally offset (corresponding to each level 130L of the storage and retrieval system), for example, as described in U.S. Patent Application No. 13 / 326,674 filed December 15, 2011, which is entirely incorporated herein by reference, and may have one transfer deck 130B at one end or side RMAE1 of a storage rack array RMA, or at several ends or sides RMAE1, RMAE2 of a storage rack array RMA.

[0018] The transport deck 130B is substantially open and configured for the non-deterministic movement of bots 110 along multiple transport lanes (for example, along the X-processing axis with respect to the bot's reference coordinate system REF shown in Figure 6) across and along the transport deck 130B. As can be understood, the transport deck 130B of each storage level 130L communicates with each of the retrieval passages 130A on each storage level 130L. Bot 110 moves along the retrieval passage 130A (for example, along the X-processing axis with respect to the bot's reference coordinate system REF as shown in Figure 6) and travels bidirectionally between the transport deck 130B and the retrieval passage 130A on each storage level 130L to access the storage spaces 130S located on rack shelves parallel to each of the retrieval passages 130A (for example, Bot 110 may access the storage spaces 130S distributed on both sides of each passage along the Y-processing axis, such that when traveling along each retrieval passage 130A, for example, referring to Figure 6, the drive wheels 202 may lead the direction of movement or the drive wheels may follow the direction of movement, thus having different opposing surfaces). As can be understood, the retrieval process from a storage array in a horizontal plane corresponding to a given storage or deck level 130L is brought about and manifests itself in a combined or integrated process along both the X and Y processing axes. As described above, the transfer deck 130B provides access for the bot 110 to each of the lifts 150 on each storage level 130L, the lifts 150 load and unload case units (for example, along the Z-axis) into and from each storage level 130L, and the bot 110 brings about the transfer of case units between the lifts 150 and the storage space 130S.

[0019] As described above, and also with reference to Figure 2A, in one embodiment, the storage structure 130 includes a plurality of storage rack modules RM composed of a three-dimensional array RMA, the racks being arranged in a passage 130A, and the passage 130A is configured for the movement of bots 110 within the passage 130A. The transport deck 130B has a non-deterministic transport surface on which the bots 100 move, and the non-deterministic transport surface 130BS has two or more juxtaposed transport lanes (e.g., a high-speed bot transport path HSTP) connected to the passage 130A. As can be understood, the juxtaposed transport lanes are juxtaposed along a common non-deterministic transport surface 130BS between both sides 130BD1, 130BD2 of the transport deck 130B. As shown in Figure 2A, in one embodiment, the passage 130A is coupled to the transport deck 130B at one side 130BD2 of the transport deck 130B, but in other embodiments, the passage is coupled to two or more sides 130BD1, 130BD2 of the transport deck 130B in substantially the same manner as described in U.S. Patent Application No. 13 / 326,674, filed December 15, 2011, the entirety of which is already incorporated herein by reference. As will be further detailed below, the other side 130BD1 of the transport deck 130B includes deck storage racks (e.g., interface station TS and buffer station BS) distributed along the other side 130BD1 of the transport deck 130B such that at least a portion of the transport deck is interposed between the deck storage racks (e.g., buffer station BS or transport station TS) and the passage 130A. The storage racks on the deck are positioned along the other side 130BD1 of the transport deck 130B so as to communicate with the bot 110 from the transport deck 130B and also with the lift module 150 (for example, the storage racks on the deck are accessed by the bot 110 from the transport deck 130B and by the lift 150 for retrieving and arranging pick faces, so that pick faces are transported between the bot 110 and the storage racks on the deck, between the storage racks on the deck and the lift 150, and ultimately between the bot 110 and the lift 150).

[0020] Referring again to Figure 1, each storage level 130L may include a charging station 130C for charging the onboard power supply of the Bot 110 on its storage level 130L, as described, for example, in U.S. Patent Application No. 14 / 209,086 filed March 13, 2014 and U.S. Patent Application No. 13 / 326,823 (now U.S. Patent No. 9,082,112) filed December 15, 2011, whose entire disclosure is incorporated herein by reference.

[0021] Bot 110 may be any suitable independently operating autonomous transport vehicle that transports and transfers case units along the X and Y processing axes throughout the storage and retrieval system 100. In one embodiment, Bot 110 is an automated, independent (e.g., free-riding) autonomous transport vehicle. Appropriate examples of bots are, for illustrative purposes only, U.S. Patent Application No. 13 / 326,674 filed on December 15, 2011; U.S. Patent Application No. 12 / 757,312 (now U.S. Patent No. 8,425,173) filed on April 9, 2010; U.S. Patent Application No. 13 / 326,423 filed on December 15, 2011; U.S. Patent Application No. 13 / 326,447 (now U.S. Patent No. 8,965,619) filed on December 15, 2011; and U.S. Patent Application No. 13 / 326,447 filed on December 15, 2011. This can be seen in the specification of U.S. Patent Application No. 13 / 326,505 (currently U.S. Patent No. 8,696,010), the specification of U.S. Patent Application No. 13 / 327,040 (currently U.S. Patent No. 9,187,244) filed on December 15, 2011, the specification of U.S. Patent Application No. 13 / 326,952 filed on December 15, 2011, the specification of U.S. Patent Application No. 13 / 326,993 filed on December 15, 2011, the specification of U.S. Patent Application No. 14 / 486,008 filed on September 15, 2014, and the specification of U.S. Provisional Patent Application No. 62 / 107,135 filed on January 23, 2015. Bot 110 (further detailed below) may be configured to place case units such as the aforementioned retail goods into one or more levels of the storage structure 130's retrieval storage section, and then selectively retrieve the ordered case units. As can be understood, in one embodiment, the processing axes X and Y of the storage array (e.g., the transport axes of the pick faces) are defined by the retrieval passage 130A, at least one transport deck 130B, bot 110, and the extendable end effectors of the bots (as described herein) (and in other embodiments, the extendable end effectors of the lift 150 also define the processing axis Y at least partially).Pick faces are transported between a receiving section of the storage and retrieval system 100 (e.g., an incoming station 160IN) where pick faces are brought into the array, and a loading filling section of the storage and retrieval system 100 (e.g., an outgoing station 160UT) where outgoing pick faces are positioned to load according to a predetermined loading order sequence. In one embodiment, the storage rack module RM and bot 110 are arranged together to bring about on-the-fly sorting of mixed case pick faces, simultaneously with transport on at least one (or, in other embodiments, at least one of each of two or more) processing axes, such that two or more pick faces are taken from one or more storage spaces and positioned at one or more pick face holding positions (e.g., a buffer station BS and a transfer station TS) different from the storage space 130S, according to a predetermined loading order sequence.

[0022] The bots 110, lift modules 150, and other suitable features of the storage and retrieval system 100 are controlled in any suitable manner, for example, by one or more central system control computers (e.g., control servers) 120, through any suitable network 180. In one embodiment, the network 180 is a wired network, a wireless network, or a combination of wired and wireless networks using any suitable type and / or number of communication protocols. In one embodiment, the control server 120 includes a collection of programs (e.g., system management software) that run substantially concurrently for substantially automatic control of the automated storage and retrieval system 100. For example, a collection of programs that run substantially concurrently and are configured to manage the storage and retrieval system 100 includes, for illustrative purposes only, controlling, scheduling and monitoring the activities of all active system components, managing inventory (e.g., which case units have been brought in and taken out, the order in which the case units were taken out, and where the case units are stored) and pick faces (e.g., one or more case units that are movable as a whole and operated as a whole by the components of the storage and retrieval system), and connecting to a warehouse management system 2500. In one embodiment, the control server 120 may be configured to control the feature components of the storage and retrieval system in the manner described herein. For the sake of brevity and ease of explanation, the term “case unit” is used herein to generally refer to both individual case units and pick faces (a pick face is formed from multiple cases that are moved together).

[0023] Referring also to Figures 1B and 1D, the rack module array RMA of the storage structure 130 includes vertical support members 1212 and horizontal support members 1200 that define a high-density automated storage array, which will be further detailed below. For example, in the retrieval passage 130A, a rail 1200S may be attached to one or more of the vertical and horizontal support members 1212, 1200, and the rail 1200S may be configured such that a bot 110 rests along the rail 1200S through the retrieval passage 130A. At least one side of the retrieval passage 130A of at least one storage level 130L may have one or more storage shelves (for example, formed by rails 1210, 1200 and slats 1210S) provided at different heights to form a plurality of shelf levels 130LS1 to 130LS4 between the storage or deck levels 130L defined by the transport deck 130B (and rails 1200S forming the passage deck). Thus, there are a plurality of rack shelf levels 130LS1 to 130LS4 corresponding to each storage level 130L, extending along one or more retrieval passages 130A communicating with the transport deck 130B of each storage level 130L. To make it clear, multiple rack shelf levels 130LS1 to 130LS4 result in each storage level 130L having a stack of case units (or layers of cases) to be stored, accessible from a common deck 1200S of each storage level 130L (for example, the stacks of cases to be stored are located between the storage levels).

[0024] As can be understood, a bot 110 traveling along the retrieval passage 130A on the corresponding storage level 130L has access to each storage space 130S available on each shelf level 130LS1-130LS4 (for example, to retrieve and place case units), and each shelf level 130LS1-130LS4 is located between adjacent vertically stacked storage levels 130L on one or more side PAS1, PAS2 (see, for example, Figure 2A) of the retrieval passage 130A. As described above, each of the storage shelf levels 130LS1-130LS4 is accessible by the bot 110 from the rail 1200 (for example, from the common retrieval passage deck 1200S corresponding to the transfer deck 130B on each storage level 130L). As can be seen in Figures 1B and 1D, there are one or more intermediate shelf rails 1210 spaced vertically (for example, in the Z direction) from one another (and from the rail 1200) to form a plurality of stacked storage spaces 130S, each accessible by bots 110 from a common rail 1200S. As can be understood, horizontal support members 1200 also form shelf rails (in addition to the shelf rails 1210) on which case units are arranged.

[0025] Each stacked shelf level 130LS1 to 130LS4 (and / or each single shelf level as described below) of the corresponding storage level 130L defines an open, non-deterministic, two-dimensional storage surface (for example, having a support surface CUSP for the case unit as shown in Figure 1D) that facilitates the dynamic assignment of pick faces in both the longitudinal direction (for example, along the length of the aisle or coinciding with the bot movement path defined by the retrieval aisle) and the lateral direction (for example, intersecting the aisle or bot movement path with respect to the depth of the rack). The dynamic assignment of pick faces and the case units constituting the pick faces is brought about, for example, by the method described in U.S. Patent No. 8,594,835, issued November 26, 2013, the entirety of which is incorporated herein by reference. For example, a control device, such as control device 120, monitors the case units stored on the shelf and the empty space or storage position between the case units. Empty storage spaces are dynamically assigned, for illustrative purposes only, such that one case of a first size is replaced by three cases of a second size, each of which, when combined, fits into the space previously reserved for the first-size case, or vice versa. The dynamic assignment substantially and continuously changes the size of the empty storage space as case units are placed on and removed from storage shelves (e.g., the storage space does not have a predetermined size and / or position on the storage shelf). Thus, the pick faces of case units (or totes) of variable length and width are placed in their respective two-dimensional storage positions on the storage shelves (e.g., on each storage shelf level 130LS1-130LS4) with minimal gaps G between adjacent stored case units / storage spaces (e.g., resulting in the removal / placement of case units without contact with other case units stored on the shelf, see Figure 1B).

[0026] As described above, the spacing between rails 1200 and 1210 (e.g., storage shelves) is variable to minimize the vertical gap VG between vertically stacked case units (e.g., to provide sufficient space for inserting and removing case units from their respective storage positions). As will be described later (for example, with respect to sections SECA and SECB in Figures 1B and 2A), in one embodiment, the vertical spacing between rails 1200 and 1210 varies along the length of each retrieval passage 130A, while in other embodiments, the spacing between rails 1200 and 1210 may be substantially continuous along the retrieval passage 130A. As will be understood and further detailed below, the spacing between rails 1200 and 1210 on one side of the retrieval passage 130A, PAS1 (Figure 2A), may differ from the spacing between rails 1200 and 1210 on the opposite side of the same retrieval passage 130A, PAS2 (Figure 2A). As can be understood, any suitable number of shelves 1210 may be provided between adjacent vertically stacked storage level 130L decks 1200S, the shelves having the same or different pitches between them (see, for example, Figure 1C; case units CUD1, CUD2, CUE1-CUE3, CUF1, CUF2 are arranged in a vertical stack on one side of the retrieval aisle, and case units CUA, CUB, CUC are arranged in a vertical stack on the opposite side of the retrieval aisle on storage shelves having substantially similar pitches). In one embodiment of the disclosed embodiment, referring to Figure 1B, the vertical pitch between rack shelf levels 130LS1-130LS4 (corresponding to each storage level 130L) is modified so that the heights Z1A-Z1E between the shelves are different rather than equal, for example, in order to minimize the vertical gap VG between the upper or top surface CUTS of case unit CU and the bottom of the storage shelves 1200, 1210 directly above the case unit.As can be seen in Figure 1B, minimizing gaps G, VG in both the horizontal and vertical directions results in the arrangement of densely packaged case units within the storage shelves to form a high-density three-dimensional rack array RMA, for example, the aisles of a high-density multi-level shelf increase the processing capacity along the X processing axis and allow for multiple retrievals of two or more case units from a common retrieval aisle in one common path of ordered / classified retrieval aisles (e.g., according to a predetermined loading unloading sequence), as described later. For example, still referring to Figure 1B, one section SECB of storage level 130L includes two storage shelves 1200, 1210, one shelf having a pitch of Z1A and the other shelf having a pitch of Z1B, with Z1A and Z1B being different from each other. This different pitch makes it possible to arrange case units CUD, CUE with different heights in upper and lower stacks on a common storage level 130L. In other embodiments, pitches Z1A, Z1B may be substantially identical. In this embodiment, storage level 130L includes another storage section SECA having three storage shelves, one shelf having a pitch of Z1E, one storage shelf having a pitch of Z1D, and the other storage shelf having a pitch of Z1C, where Z1E, Z1D, and Z1C are different from each other. In other embodiments, at least two of the pitches Z1E, Z1D, and Z1C are substantially identical. In one embodiment, the pitch between shelves is arranged such that larger and / or heavier case units CUC, CUE are positioned closer to deck 1200S than smaller and / or lighter case units CUD, CUA, CUB. In other embodiments, the pitch between shelves is arranged such that case units are positioned at any suitable position, which may or may not be related to the size and weight of the case units.

[0027] In another embodiment, the vertical pitch between at least some rack shelves is identical such that the heights Z1A to Z1E between at least some shelves are equal, but the vertical pitch between other shelves is different. In yet another embodiment, the pitch between rack shelf levels 130LS1 to 130LS4 on one storage level is constant (for example, the rack shelf levels are substantially equally spaced in the Z direction), but the pitch between rack shelf levels 130LS1 to 130LS4 on different storage levels is different constant pitches.

[0028] In one embodiment, a storage space 130S, defined by storage shelf levels 130LS1 to 130LS4 between storage or deck level 130L, accommodates case units of different heights, lengths, widths, and / or weights on different shelf levels 130LS1 to 130LS4, as described, for example, in U.S. Nonprovisional Patent Application No. 14 / 966,978 filed December 11, 2015, and U.S. Provisional Patent Application No. 62 / 091,162 filed December 12, 2014, whose entire disclosure is incorporated herein by reference. For example, still referring to Figure 1B, storage level 130L includes a storage section having at least one intermediate shelf 1210. In the illustrated example, one storage section includes one intermediate shelf 1210, while another storage section includes two intermediate shelves 1210 to form shelf levels 130LS1 to 130LS4. In one embodiment, the pitch Z1 between storage levels 130L may be any suitable pitch, such as about 32 inches to about 34 inches, and in another embodiment, the pitch may be greater than about 34 inches and / or less than about 32 inches. Any suitable number of shelves may be provided between decks 1200S of adjacent vertically stacked storage levels 130L, the shelves having the same or different pitches between them (see, for example, Figure 1C, where case units CUD1, CUD2, CUE1-CUE3, CUF1, CUF2 are arranged in a vertical stack on one side of the retrieval aisle, and case units CUA, CUB, CUC are arranged in a vertical stack on the opposite side of the retrieval aisle on storage shelves having substantially similar pitches).

[0029] In one embodiment of the disclosed embodiments, the storage or deck level 130L (e.g., the surface on which bot 110 moves) is arranged at any suitable predetermined pitch Z1, which is not an integer multiple of the intermediate shelf pitches Z1A to Z1E, for example. In other embodiments, the pitch Z1 may be an integer multiple of the intermediate shelf pitch, and the shelf pitch may be substantially equal to the pitch Z1, for example, such that the corresponding storage space has a height substantially equal to the pitch Z1. As can be understood, the shelf pitches Z1A to Z1E are substantially separate from the pitch Z1 of the storage level 130L and correspond to the heights of typical case units as shown in Figure 1B. In one embodiment of the disclosed embodiments, case units of different heights are dynamically allocated or distributed along each aisle in the storage space 130S having shelf heights commensurate with the heights of the case units. The remaining space between storage levels 130L can be freely used for dynamic allocation of cases of corresponding heights, both along the length of the aisles that coincide with the case units to be stored (for example, in the X direction relative to the rack's reference coordinate system REF2, where the X direction is the same as the reference coordinate system of the bot when the bot moves along the retrieval aisle 130A) and along the case units to be stored. As can be understood, dynamically allocating case units of different heights to shelves with different pitches results in layers of stored cases of different heights between storage levels 130L on both sides of each retrieval aisle 130A, and each case unit is dynamically distributed along a common retrieval aisle 130A such that each case unit within each layer of stored cases is independently accessible (for example, for retrieval / placement) by bots in the common aisle.Each aisle length may include multiple case units of different heights, and each rack shelf at each shelf level may be filled by dynamic allocation / distribution (for example, to fill the space of a three-dimensional rack module array RMA in length, width, and height to provide a high-density storage array). This high-density arrangement / allocation of case units and storage shelves, through optimized case unit SKU distribution, results in maximum efficiency in the use of storage space / volume between storage levels of 130L, and therefore, maximum efficiency of the rack module array RMA.

[0030] In one embodiment, referring to Figures 1E and 6A, each of the storage levels 130L includes a single-level storage shelf for storing a single-level case unit (for example, each storage level includes a single-case unit support surface CUSP), and the bot 110 is configured to transport the case units to and from the storage shelves of each storage level 130L. For example, the bot 110' shown in Figure 6A is substantially similar to the bot 110 described herein, but the bot 110' does not provide sufficient Z-movement of the transport arm 110PA for positioning the case units on multiple storage shelf levels 130LS1 to 130LS4 (accessible from a common rail 1200S) as described above. Here, the transfer arm drive unit 250 (which may be substantially equivalent to one or more of the drive units 250A, 250B) includes a Z movement sufficient to lift the case unit from the case unit support surface CUSP of a single-level storage rack in order to transfer the case unit to and from the loading area 110PL and to transfer the case unit between the fingers 273 of the transfer arm 110PA and the loading bed 110PB. A suitable example of bot 110' can be found, for example, in U.S. Patent Application No. 13 / 326,993, filed December 15, 2011, the entirety of which is incorporated herein by reference.

[0031] In one embodiment of the disclosed features, also with reference to Figure 2A, along each retrieval passage 130A, the rack shelves 1210 (including rack shelves formed by rails 1200) are divided longitudinally (for example, in the X direction along the length of the retrieval passage 130A with respect to the reference coordinate system RFE2 of the storage structure) into SECA, SECB. The shelf sections SECA, SECB of the passage are ordered / adapted relative to each other, for example, based on the retrieval sequence of bots 110 that move back and forth along the passage in a common path and retrieve case units specified by a common order handling (for example, based on an order retrieval sequence). In other words, the bot 110 creates a single path (e.g., going in one direction) going down a single or common picking passage, while picking up one or more case units from the shelf sections SECA, SECB of the passage on the common side of the picking passage 130A, in order to construct a pick face on the bot 110, and the pick face includes case units that are placed on the bot according to an order filling / order unloading sequence as further detailed below. The rack sections SECA, SECB of the passage each include intermediate shelves in the manner described above. In other embodiments, some of the shelves of the passage do not include intermediate shelves, while others do.

[0032] In one embodiment, the rack sections SECA, SECB of the ordered aisles include different shelf pitches between sections SECA, SECB. For example, rack section SECA of the aisle has shelves with one or more pitches, while rack section SECB of the aisle has shelves with one or more different pitches (e.g., different from the shelf pitches of section SECA). According to an aspect of the disclosed embodiment, the pitch of at least one intermediate shelf in rack sections SECA, SECB of one aisle is associated with the pitch of at least one intermediate shelf in the other rack section SECA, SECB of the ordered aisles of a common pick-up aisle 130A. The different pitches of the intermediate shelves 1210 in rack sections SECA, SECB of the ordered aisles are selected so as to be associated and to result in a plurality (at least two) ordered pick-ups (i.e., pick-ups in order sequence) by bot 110 from shelves of different pitches in the common path of the common pick-up aisle 130A, according to a pick-up sequence of mixed SKU loads (e.g., pallet loading onto common pallet loads). As can be understood, the unloading of mixed loads from the storage and unloading system 100 (for example, for filling truck load ports / pallet loads) is ordered in a predetermined sequence according to the various loads exiting the unloading passage (for example, the passage from which case units are unloaded for transfer to pallets going out), and the pitch of the shelves in the ordered sections SECA, SECB facilitates the unloading of two or more case units in an ordered sequence according to the order of the unloading sequence of loads in a common unloading passage route (for example, in one route of the common unloading passage, two or more case units are unloaded from the common unloading passage in a predetermined order).The shelf pitches of the ordered rack sections SECA, SECB in different aisles are associated to enhance the possibility of ordered multiple retrievals (retrieval of two or more case units from a single aisle with a single path as described above) so that multiple retrievals are performed by the order processing path of each bot along each aisle, and are associated so that the majority of cases to be retrieved by the bot 110 in the storage and retrieval system 100 for the purpose of common load unloading (e.g., common pallet loads) are retrieved by the common bot 110 in an ordered order according to the load unloading sequence within a single path of the common retrieval aisle (e.g., two or more cases retrieved by the bot 110 are retrieved from the same retrieval aisle of a single path, and e.g., the bot moves in a single direction as it passes through the retrieval aisle). As can be understood, in one embodiment of the disclosed embodiment, both sides of the retrieval aisle 130A have rack sections SECA, SECB of ordered aisles, and one ordered section may be adapted to one or more sections on the same side PAS1, PAS2 of the common retrieval aisle 130A. To make it clear, the rack sections of the adapted passage may be arranged adjacent to each other or spaced apart from each other along the retrieval passage 130A.

[0033] Referring again to Figure 2A, each transport deck or storage level 130L includes one or more lift pick-face interface / transfer stations TS (hereinafter referred to as interface stations TS), and case units or totes (of single or combined case pick-faces) are transported on the transport deck 130B between the lift load handling device LHD and the bots 110. The interface stations TS are positioned on the transport deck 130B, opposite the pick-up passage 130A and rack module RM, so that the transport deck 130B is interposed between the pick-up passage and each interface station TS. As described above, each bot 110 on each pick-up level 130L has access to each storage position 130S, each pick-up passage 130A and each lift 150 on each storage level 130L, so each bot 110 also has access to each interface station TS on its respective level 130L. In one embodiment, the interface station TS is offset from the high-speed bot transport path HSTP along the transport deck 130B such that the bot's access to the interface station TS is nondeterministic with respect to the bot's speed on the high-speed transport path HSTP. Thus, each bot 110 can move a case unit (or pick face, e.g., one or more cases constructed by the bot) from each interface station TS to each storage space 130S corresponding to the deck level, and vice versa.

[0034] In one embodiment, the interface station TS is configured for the passive transfer (e.g., handover) of a case unit (and / or pick face) between a bot 110 and a load handling device LHD of a lift 150 (e.g., the interface station TS does not have moving parts for transporting the case unit), as further detailed below. For example, referring also to Figure 2B, the interface station TS and / or buffer station BS include one or more stacked levels TL1, TL2 of a transport rack shelf RTS, which in one embodiment is similar to the storage shelf described above (e.g., each formed by rails 1210, 1200 and slats 1210S), such that the handover (e.g., picking up and placing) of the bot 110 occurs in a passive manner substantially similar to the method (as described herein) between the bot 110 and the storage space 130S where the case unit or tote is transferred to and from the shelf (e.g., to take advantage of the lifting capacity of the bot 110 relative to the stacked rack shelf RTS). In one embodiment, a buffer station BS on one or more of the stacked levels TL1, TL2 also functions as a transfer / interface station to the load handling device LHD of the lift 150. In one embodiment, if a bot 110 such as bot 110' is configured for the transfer of case units to a single level 130L of storage shelving, the interface station TS and / or buffer station BS also include a single-level transfer rack shelf (substantially similar to the storage rack shelf of storage level 130L described above with respect to Figure 1D, for example). As can be understood, the operation of a storage and retrieval system with a bot 110' providing a single-level storage and transfer shelf is substantially similar to that described herein.As can also be understood, the transfer (e.g., retrieval and placement) of the load handling device LHD of case units (e.g., individual case units or pick faces) and totes to stacked rack shelves RTS (and / or single-level rack shelves) occurs in a substantially passive manner similar to the method (as described herein) in which case units or totes are transferred between the bot 110 and the storage space 130S to and from the shelves. In other embodiments, the shelves may include a transfer arm (the transfer arm is substantially similar to the transfer arm 110PA of the bot 110 shown in Figure 6, but movement in the Z direction may be omitted if the transfer arm is incorporated into the shelf of the interface station TS) for retrieving and placing case units or totes from one or more load handling device LHDs of the bot 110 and the lift 150. A suitable example of an interface station with an active transport arm is described, for example, in U.S. Patent Application No. 12 / 757,354, filed on April 9, 2010, the entirety of which is incorporated herein by reference.

[0035] In one embodiment, the positioning of the bot 110 relative to the interface station TS occurs in substantially the same manner as the positioning of the bot relative to the storage space 130S. For example, in one embodiment, the positioning of the bot 110 relative to the storage space 130S and the interface station TS occurs in substantially the same manner as described in U.S. Patent Application No. 13 / 327,035 (now U.S. Patent No. 9,008,884), filed December 15, 2011, and U.S. Patent Application No. 13 / 608,877 (now U.S. Patent No. 8,954,188), filed September 10, 2012, the entirety of which is incorporated herein by reference. For example, referring to Figures 1 and 1D, the bot 110 includes one or more sensors 110S that detect a slat 1210S or a positioning feature section 130F (such as an opening, reflective surface, or RFID tag) positioned on / within the rail 1200. The slats and / or positioning feature units 130F are arranged to determine, for example, the position of the bot 110 in the storage and retrieval system relative to the storage space and / or interface station TS. In one embodiment, the bot 110 includes a control device 110C that counts, for example, the slats 1210S, in order to at least partially determine the position of the bot 110 in the storage and retrieval system 100. In another embodiment, the positioning feature units 130F may be arranged to form an absolute or incremental encoder that, when detected by the bot 110, results in a determination of the position of the bot 110 in the storage and retrieval system 100.

[0036] As can be understood, referring to Figure 2B, the transport rack shelf RTS of each interface / transfer station TS defines a multi-load station on a common transport rack shelf RS (for example, having one or more storage case holding positions to hold a corresponding number of case units or totes). As described above, each load in the multi-load station is a single case unit / tote or a pick face of multiple cases (for example, having multiple case units / totes that are moved together) that is picked up and placed by either a bot or a load handling device LHD. As can be understood, the bot positioning described above allows the bot 110 to position itself relative to the multi-load station in order to pick up and place case units / totes and pick faces from one of the predetermined holding positions of the multi-load station. The interface / transfer station TS defines a multi-position buffer (for example, a buffer having one or more case holding positions, see Figure 4B, which is positioned, for example, along the X-axis of the bot 110 when the bot 110 interacts with the interface station TS) where incoming and / or outgoing case units / totes and pick faces are temporarily stored when they are transferred between the bot 110 and the load handling device LHD of the lift 150.

[0037] In one embodiment, one or more peripheral buffer / transfer stations BS (substantially similar to interface stations TS, and hereinafter referred to as buffer stations BS) are also positioned on the opposite side of the transport deck 130B from the take-out passage 130A and rack module RM, such that the transport deck 130B is interposed between the take-out passage and each buffer station BS. The peripheral buffer stations BS are scattered between interface stations TS or, in one embodiment, are linear with the interface stations TS as shown in Figures 2A and 2B. In one embodiment, the peripheral buffer stations BS are formed by rails 1210, 1200 and slats 1210S and are an extension (albeit a separate section) of the interface stations TS (for example, the interface stations and peripheral buffer stations are formed by common rails 1210, 1200). Thus, in one embodiment, the peripheral buffer stations BS include one or more stacked levels TL1, TL2 of transport rack shelves RTS as described above with respect to the interface stations TS, but in other embodiments, the buffer stations include a single level of transport rack shelves. The peripheral buffer station BS defines a buffer where case units / totes and / or pick faces are temporarily stored when they are being transferred from one bot 110 to another different bot 110 on the same storage level 130L, as further detailed below. As can be understood, in one embodiment, the peripheral buffer station is located at any suitable location in the storage and retrieval system, including any location within the retrieval passage 130A and along the transfer deck 130B.

[0038] Still referring to Figures 2A and 2B, in one embodiment, the interface station TS is positioned along the transport deck 130B in a manner similar to a parking space on the side of a road, so that the bot 110 “parallel parks” at a given interface station TS in order to transport case units to and from one or more shelves RTS at one or more levels TL1, TL2 of the interface station TS. In one embodiment, the orientation of the bot 110's transport at the interface station TS (for example, when parallel parked) is the same as the orientation of the bot 110 when it is moving along the high-speed bot transport path HSTP (for example, the interface station is substantially parallel to the direction of bot movement on the transport deck and / or the side of the transport deck on which the lift 150 is positioned). Interaction of the bot 110 with the peripheral buffer station BS also occurs by parallel parking such that the orientation of the bot 110's transport at the peripheral buffer station BS (for example, when parallel parked) is the same as the orientation of the bot 110 when it is moving along the high-speed bot transport path HSTP.

[0039] In another embodiment, referring to Figures 3A and 3B, at least the interface station TS is located on an extension or pier 130BD extending from the transport deck 130B. In one embodiment, the pier 130BD is similar to an retrieval passage on which bots 110 move along rails 1200S to which horizontal support members 1200 are fixed (in substantially the same manner as described above). In another embodiment, the moving surface of the pier 130BD may be substantially the same as the moving surface of the transport deck 130B. Each pier 130BD is located on the side of the transport deck 130B, such as the side opposite to the retrieval passage 130A and rack module RM, such that the transport deck 130B is interposed between the retrieval passage and each pier 130BD. The pier 130BD extends from the transport deck at a non-zero angle with respect to at least a portion of the high-speed bot transport path HSTP. In another embodiment, peer 130BD extends from any suitable portion of the transport deck 130B, including the ends 130BE1, 130BE2 of the transport deck 130BD. As can be understood, a peripheral buffer station BSD (substantially similar to the peripheral buffer station BS described above) may also be located along at least a portion of peer 130BD.

[0040] Referring next to Figures 4A, 4B, and 5, as described above, in one embodiment, the interface station TS is a passive station, and the load transfer device LHD of the lifts 150A, 150B has an active transfer arm or retrieval head 4000A, 4000B. In one embodiment, the receiving lift module 150A and the outbound lift module 150B have different types of retrieval heads (described later), but in other embodiments, the receiving lift module 150A and the outbound lift module 150B have the same type of retrieval head, similar to one of the retrieval heads described later (for example, both lifts 150A, 150B have retrieval head 4000A, or both lifts 150A, 150B have retrieval head 4000B). The retrieval heads of the lifts 150A, 150B may define, at least in part, the Y processing axis as described herein. In one embodiment, both the inbound and outbound lift modules 150A, 150B have a vertical mast 4002 along which a slide 4001 moves under the power of any suitable drive unit 4002D (connected to, for example, a control server 120) configured to raise and lower the slide (and the retrieval heads 4000A, 4000B mounted thereon). The inbound lift module 150A includes a retrieval head 4000A mounted on the slide 4001 such that when the slide moves vertically, the retrieval head 4000A moves vertically with the slide 4001. In this embodiment, the retrieval head 4000A includes one or more tines or fingers 4273 mounted on a base member 4272. The base member 4272 is movably mounted on one or more rails 4360S of a frame 4200 which is later mounted on the slide 4001. Any suitable drive unit 4005 (which may be smaller than the drive unit 4002D and therefore substantially the same in form as the drive unit 4002D, but not necessarily the same in capacity), such as a belt drive unit, chain drive unit, screw drive unit, or gear drive unit, is attached to the frame 4200 and connected to the base member 4272 to drive the base member 4272 (which has fingers) in the direction of arrow 4050.

[0041] The retrieval lift module 150B also includes a retrieval head 4000B attached to the slide 4001 such that when the slide moves vertically, the retrieval head 4000B moves vertically with the slide 4001. In this embodiment, the retrieval head 4000B includes one or more retrieval head portions or effectors (e.g., transport arms) LHDA, LHDB, each having one or more tines or fingers 4273 attached to their respective base members 4272A. Each base member 4272A is movably mounted to one or more rails 4360SA of a frame 4200A which is later attached to the slide 4001. Any suitable drive unit 4005A, such as a belt drive, chain drive, screw drive, or gear drive, is mounted on the frame 4200A and connected to each base member 4272A to drive each base member 4272A (equipped with fingers) in the direction of arrow 4050 (each effector has its own drive unit so that each effector is independently movable in the direction of arrow 4050). Two effectors LHDA and LHDB are shown on the extraction head 4000B, but the extraction head 4000B includes any suitable number of effectors corresponding to the number of case unit / pick face holding positions of the interface station TS, for example, so that the case units / pick faces are extracted individually from the interface station TS as further detailed below.

[0042] As can be understood, the lift modules 150A, 150B are under the control of any suitable control device, such as a control server 120, so that when retrieving and positioning case units, the retrieval heads are raised and / or lowered to a predetermined height corresponding to an interface station TS at a predetermined storage level 130L. As can be understood, the lift modules 150A, 150B provide a Z-axis (relative to both the bot reference coordinate system REF and the rack reference coordinate system REF2) of the storage and retrieval system, which allows the discharge lift module 150B to sort case units on the fly for transport to a discharge station 160US as described below. At the interface station TS, the retrieval heads 4000A, 4000B or their individual parts (e.g., effectors LHDA, LHDB) are extended so that fingers 4273 engage between slats 1210S (shown in Figure 4B) beneath the case unit being retrieved, corresponding to one or more case unit holding positions at the interface station TS from which one or more case units are retrieved. Lifts 150A and 150B raise the retrieval heads 4000A and 4000B to lift case units from the slats 1210S, and retract the retrieval heads 4000A and 4000B to transport case units to another level of the storage and retrieval system, such as to transport case units to the discharge station 160UT. Similarly, to position one or more case units, the retrieval heads 4000A and 4000B or their individual parts (e.g., effectors LHDA and LHDB) are extended so that the fingers 4273 are above the slats, corresponding to the holding positions of one or more case units at the interface station TS where the one or more case units are positioned. Lifts 150A and 150B lower the retrieval heads 4000A and 4000B to position the case units on the slats 1210S and so that the fingers 4273 engage between the slats 1210S below the case unit being retrieved.

[0043] Referring now to Figure 6, as described above, the bot 110 includes a transport arm 110PA that brings about the retrieval and placement of case units from stacked storage spaces 130S, interface stations TS and peripheral buffer stations BS, BSD (for example, the storage spaces, interface stations and / or peripheral buffer stations may be further defined in the X and Y directions with respect to either the rack reference coordinate system REF2 or the bot reference coordinate system REF, through the dynamic allocation of case units as described above). The bot defines an X processing axis and also defines a Y processing axis (for example, with respect to the bot reference coordinate system REF), as can be understood. The bot 110 transports case units between each lift module 150 on each storage level 130L and each storage space 130S, as described above. The bot 110 includes a frame 110F having a drive section 110DR and a loading section 110PL. The drive section 110DR includes one or more drive wheel motors, each connected to each drive wheel 202, to propel the bot 110 along the X direction (with respect to the bot reference coordinate system REF to define the X processing axis). As can be understood, the X axis of the bot movement coincides with the storage position when the bot 110 moves through the retrieval passage 130A. In this embodiment, the bot 110 includes two drive wheels 202 positioned on either side of the bot 110 at the end 110E1 of the bot 110 (e.g., the first longitudinal end) to support the bot 110 on a suitable drive surface, but in other embodiments, any suitable number of drive wheels are provided on the bot 110. In one embodiment, each drive wheel 202 is controlled independently so that the bot 110 can be steered through differential rotation of the drive wheels 202, but in other embodiments, the rotations of the drive wheels 202 may be coupled to rotate at substantially the same speed.To support the bot 110 on the drive surface, suitable wheels 201 are attached to the frames on both sides of the bot 110 at the ends 110E2 of the bot 110 (for example, the second longitudinal ends). In one embodiment, the wheels 201 are freely rotating caster wheels, thereby allowing the bot 110 to pivot through the differential rotation of the drive wheels 202 to change the direction of movement of the bot 110. In other embodiments, the wheels 201 are maneuverable wheels that change direction under the control of a bot control device 110C (configured to provide control of the bot 110 as described herein) to change the direction of movement of the bot 110. In one embodiment, the bot 110 includes, for example, one or more guide wheels 110GW at one or more corners of the frame 110F. The guide wheel 110GW may interact with a storage structure 130, such as a guide rail (not shown) in the retrieval passage 130A, on the transfer deck 130B and / or at the interface or transfer station, to interact with the lift module 150 to guide and / or position the bot 110 a predetermined distance to and from the location where one or more case units are to be placed and / or from the location where one or more case units are to be retrieved, as described in, for example, U.S. Patent Application No. 13 / 326,423 filed December 15, 2011, whose entire disclosure is incorporated herein by reference. As described above, the bot 110 may enter the retrieval passage 130A having different opposing directions to access the storage spaces 130S located on both sides of the retrieval passage 130A. For example, the bot 110 may enter the retrieval passage 130A with its end 110E2 leading the direction of movement, or with its end 110E1 leading the direction of movement.

[0044] The loading section 110PL of the bot 110 includes a loading bed 110PB, a fence or reference member 110PF, a transport arm 110PA, and a pusher bar or member 110PR. In one embodiment, the loading bed 110PB includes one or more rollers 110RL mounted laterally to the frame 110F (for example, with respect to the longitudinal axis LX of the bot) so that one or more case units carried within the loading section 110PL can be moved longitudinally along the longitudinal axis of the bot (for example, so that they are justified with respect to a predetermined position in the frame / loading section and / or a position reference for one or more case units) to position the case units (for example, forward / backward alignment of the case units in the longitudinal direction) in relation to other case units within the loading section 110PL. In one embodiment, the roller 110RL may be driven by any suitable motor to move the case unit within the loading section 110PL (for example, to be rotated around its respective axis). In another embodiment, the bot 110 includes one or more longitudinally movable pusher bars (not shown) that push the case unit beyond the roller 110RL to move the case unit to a predetermined position within the loading section 110PL. The longitudinally movable pusher bars may be substantially similar to those described, for example, in U.S. Patent Application No. 13 / 326,952, filed December 15, 2011, the entirety of which is already incorporated herein by reference. The pusher bar 110PR is movable in the Y direction with respect to the reference coordinate system REF of the bot 110 to bring about lateral alignment of the case unit within the loading area 110PL along the take-out head 270 of the fence 110PF and / or the transport arm 110PA, as described in the method of U.S. Provisional Patent Application No. 62 / 107,135 filed on January 23, 2015, whose entire disclosure is already incorporated herein by reference.

[0045] Still referring to Figure 6, the case unit is placed on and removed from the loading bed 110PB by a transfer arm 110PA along the Y processing axis. The transfer arm 110PA includes a lift mechanism or unit 200 located substantially within the loading section 110PL, as described, for example, in U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, whose entire disclosure is already incorporated herein by reference. The lift mechanism 200 provides both coarse and fine placement of the pick faces gripped by the bot 110, which are lifted vertically to the location of the storage structure 130 in order to take out and / or place the pick faces and / or individual case units into the storage space 130S (for example, on each storage level 130L where the bot 110 is located). For example, the lift mechanism 200 allows for the removal and placement of case units at multiple elevated storage shelf levels 130LS1-130LS4, TL1, and TL2, accessible from a common retrieval passage or interface station deck 1200S (see, for example, Figures 1B, 2B, and 3B).

[0046] The lift mechanism 200 is configured to perform combined robot axis movements (e.g., combined substantially simultaneous movements of the pusher bar 110PR, the lift mechanism 200, the extension of the retrieval head, and forward / rear alignment mechanisms, such as the longitudinally movable pusher bar described above) so that different / multiple SKUs or multiple retrieval loads can be operated by the bot. In one embodiment, the operation of the lift mechanism 200 is independent of the operation of the pusher bar 110PR, as described below. Separating the axes of the lift mechanism 200 and the pusher bar 110PR results in a combined retrieval / placement sequence, which results in a reduction in retrieval / placement cycle time, an increase in the processing capacity of the storage and retrieval system, and / or an increase in the storage density of the storage and retrieval system as described above. For example, the lift mechanism 200 results in the retrieval and placement of case units at multiple raised storage shelf levels accessible from a common retrieval passage and / or interface station deck 1200S as described above.

[0047] The lift mechanism may be configured in any suitable way so that the take-out head 270 of the bot 110 moves bidirectionally along the Z axis (for example, reciprocating in the Z direction, see Figure 6). In one embodiment, the lift mechanism includes a mast 200M, and the take-out head 270 is movablely mounted to the mast 200M in any suitable way. The mast is movablely mounted to a frame in any suitable way so that it is movable along the lateral axis LT of the bot 110 (for example, in the Y direction to define the Y processing axis). In one embodiment, the frame includes guide rails 210A, 210B to which the mast 200 is slidably mounted. Transfer arm drive units 250A, 250B may be mounted to the frame to provide movement of the transfer arm 110PA along at least the lateral axis LT (for example, the Y axis) and the Z axis. In one embodiment, the transfer arm drive units 250A, 250B include an extension motor 301 and a lift motor 302. The extension motor 301 may be mounted on the frame 110F and may be connected to the mast 200M in any suitable way, such as by a belt and pulley transmission 260A, a screw drive transmission (not shown), and / or a gear drive transmission (not shown). The lift motor 302 may be mounted on the mast 200M and may be connected to the take-up head 270 in any suitable way, such as by a belt and pulley transmission 271, a screw drive transmission (not shown), and / or a gear drive transmission (not shown). As an example, the mast 200M includes guides such as guide rails 280A, 280B, and the take-up head 270 is mounted along the guide rails 280A, 280B for guided movement in the Z direction along the guide rails 280A, 280B. In another embodiment, the take-up head is mounted on the mast in any suitable way for guided movement in the Z direction. With respect to the transmission section 271, the belt 271B of the belt and pulley transmission section 271 is fixed and connected to the extraction head 270 such that when the belt 271 moves (for example, driven by the motor 302), the extraction head 270 moves together with the belt 271 and is driven bidirectionally in the Z direction along the guide rails 280A and 280B.As can be understood, when a screw drive is used to drive the extraction head 270 in the Z direction, the nut may be attached to the extraction head 270 such that when the screw is turned by the motor 302, the engagement between the nut and the screw causes the extraction head 270 to move. Similarly, when a gear drive transmission is used, a rack and pinion or any other suitable gear drive may drive the extraction head 270 in the Z direction. In other embodiments, any suitable linear actuator is used to move the extraction head in the Z direction. The transmission 260A for the extension motor 301 is substantially the same as that described herein with respect to the transmission 271.

[0048] Still referring to Figure 6, the retrieval head 270 of the bot 110 transports the case unit between the bot 110 and case unit retrieval / placement locations such as storage space 130S, peripheral buffer stations BS, BSD, and / or interface station TS (see Figures 2A-3B), and in other embodiments, directly between the bot 110 and the lift module 150. In one embodiment, the retrieval head 270 includes a base member 272, one or more tines or fingers 273A-273E, and one or more actuators 274A, 274B. The base member 272 is mounted on the mast 200M as described above so as to rest along guide rails 280A, 280B. One or more tines 273A-273E are attached to the base member 272 at their proximal ends such that the distal ends (e.g., free ends) of the tines 273A-273E are cantilevered from the base member 272. Referring again to Figure 1D, the tines 273A-273E are configured for insertion between the slats 1210S that form the case unit support surface CUSP of the storage rack.

[0049] One or more of the tines 273A to 273E are movable to the base member 272 (such as on a slide / guide rail similar to those described above) so as to be movable in the Z direction. In one embodiment, any number of tines are mounted to the base member 272, but in the embodiment shown in the drawings, for example, five tines 273A to 273E are mounted to the base member 272. Any number of the tines 273A to 273E are movable to the base member 272, but in the embodiment shown in the drawings, for example, the outermost tines 273A and 273E (relative to the center line CL of the take-out head 270) are movable to the base member 272, while the remaining tines 273B to 273D are immovable relative to the base member 272.

[0050] In this embodiment, the retrieval head 270 uses only three tines 273B-273D to transport smaller case units (and / or groups of case units) to and from the bot 110, and uses five tines 273A-273E to transport larger case units (and / or groups of case units) to and from the bot 110. In other embodiments, fewer than three tines are used to transport smaller case units (for example, when three or more tines are movably mounted on the base member 272). For example, in one embodiment, all but one tine 273A-273E are movably mounted on the base member such that the smallest case unit being transported to and from the bot 110 has a width of about X1, the distance between the slats 1210S, without interfering with other case units on the storage rack (see Figure 1D).

[0051] The immovable tines 373B-373D define the picking surface SP of the picking head 270 and are used when transporting case units (and / or pick faces) of all sizes, while the movable tines 373A, 373E are selectively raised and lowered (for example, in the Z direction by actuators 274A, 274B) relative to the immovable tines 373B-373D to transport larger case units (and / or pick faces). Referring still to Figure 6, an example is shown in which all of the tines 273A to 273E are positioned such that the case unit support surface SF of each tine 273A to 273E coincides with the removal surface SP of the removal head 270. However, as can be understood, the case unit support surfaces SF of the tines 273A, 273E are offset (for example, downward) from the removal surface SP, and the two end tines 273A, 273E are movable so as to be positioned downward (for example, in the Z direction) relative to the other tines 273B to 273D, so as not to come into contact with one or more case units gripped by the removal head 270 and to not interfere with unremoved case units located in the storage space 130S or any other suitable case unit holding position on the storage shelf.

[0052] The movement of tines 273A to 273E in the Z direction is brought about by one or more actuators 274A, 274B mounted at any suitable location on the transfer arm 110PA. In one embodiment, one or more actuators 274A, 274B are mounted on the base member 272 of the extraction head 270. One or more actuators are any suitable actuators, such as linear actuators, that can move one or more tines 273A to 273E in the Z direction. For example, in the embodiment shown in Figure 6, there is one actuator 274A, 274B for each of the movable tines 273A, 273E so that each movable tine is independently movable in the Z direction. In other embodiments, one actuator may be connected to two or more movable tines so that two or more movable tines move together in the Z direction.

[0053] As can be understood, the movable mounting of one or more tines 273A-273E on the base member 272 of the pick-up head 270 provides full support for large case units and / or pick faces on the pick-up head 270, while also providing the ability to pick up and place smaller case units without interfering with other case units located, for example, on storage shelves, interface stations and / or peripheral buffer stations. The ability to pick up and place case units of various sizes without interfering with other case units on storage shelves, interface stations and / or peripheral buffer stations reduces the size of the gap GP (see Figure 1B) between case units on the storage shelves. As can be understood, since tines 273B-273D are fixed to the base member 272, the raising and lowering of case units and / or pick faces to and from the case unit holding position is brought about solely by the lift motors 301, 301A, so there is no overlapping motion when picking up / placing case units.

[0054] Referring again to Figure 6, it should also be noted that the pusher bar 110PR is movable independently of the transfer arm 110PA. The pusher bar 110PR is movable to the frame in any suitable manner, such as a guide rod and slide configuration, and is actuated along the Y direction (for example, a direction substantially parallel to the extension / retraction direction of the transfer arm 110PA). In one embodiment, at least one guide rod 360 is mounted within the loading section 110PL so as to extend laterally with respect to the longitudinal axis LX of the frame 110F. The pusher bar 110PR may include at least one slide member 360S configured to engage with each guide rod 360 and slide along it. In one embodiment, at least the guide rod / slide configuration is connected within the loading section 110PL to hold the pusher bar 110PR. The pusher bar 110PR is actuated by any suitable motor and transmission, such as a motor 303 and transmission 303T. In one embodiment, the motor 303 is a rotary motor, and the transmission unit 303T is a belt and pulley transmission unit. In another embodiment, the pusher bar 110PR may be actuated by a linear actuator that has substantially no rotating parts.

[0055] The pusher bar 110PR is positioned within the loading section 110PL so as to be substantially perpendicular to the roller 110RL and so as not to interfere with the pick-up head 270. As can be seen in Figure 10B, the bot 110 is a transport structure such that at least one case unit is supported on the roller 110RL (for example, the rollers collectively form a loading bed). In the transport structure, the tines 273A-273E of the pick-up head 270 are interlocked with the roller 110RL and are positioned below (along the Z direction) the case unit support surface RSP (see Figure 10) of the roller 110RL. The pusher bar 110PR is configured with a groove 351 (Figure 10C) into which the tines 273A-273E are inserted, and sufficient clearance is provided within the groove 351 to allow the tines to move below the case unit support surface RSP and to allow the pusher bar 110PR to move freely without interference from the tines 273A-273E. The pusher bar 110PR also includes one or more openings through which the roller 110RL passes, and the openings are sized to allow the roller to rotate freely around its respective axis. As can be understood, the independently operating pusher bar 110PR does not interfere with the roller 110RL, the lateral extension (e.g., in the Y direction) of the transfer arm 110PA, and the raising / lowering of the take-up head 270.

[0056] As described above, since the pusher bar 110PR is a separate, independent axis of the bot 110 that operates without interference from the extension and lifting axes of the take-out head 270, the pusher bar 110PR can operate substantially simultaneously with the lifting and / or extension of the transfer arm 110PA. The combined axial movement (e.g., simultaneous movement of the pusher bar 110PR with the extension and / or lifting axis of the transfer arm 110PA) results in an increased loading operation capacity along the Y processing axis, resulting in ordered multiple take-outs of two or more case units from a common take-out passage (e.g., by a predetermined load unloading sequence) along one common path of the take-out passage. For example, referring to Figures 10-10A, during multiple take-out / placement sequences of the transfer arm 110PA, the pusher bar 110PR is pre-positioned at a predetermined distance X2 from the contact depth X3 (for example, the depth of the tines occupied by the case unit and / or pick face CU when it is taken out / placed from storage space or other case unit holding position) (when the case unit and / or pick face is taken out and transferred into the loading section 110PL) (Figure 14, block 1100). The distance X2 is the minimum distance that provides sufficient clearance between the pusher bar 110PR and the case unit to allow the case unit to be seated on the roller 110RL. When the case unit CU is lowered onto the roller 110RL (Figure 14, block 1110), the distance the pusher bar 110PR travels to contact the case unit CU is a shorter distance X2 compared to the distance X4 traveled by a conventional transport vehicle when moving from the rear 402 of the loading section 110PL (relative to the lateral and access side 401 of the loading section 110PL). When the case unit CU is lowered by the transport arm 110PA and transported onto the roller 110RL so that it is supported only by the roller 110RL, the pusher bar 110PR is actuated forward (relative to the lateral and access side 401 of the loading section 110PL) to align the case unit CU (Figure 14, block 1120).For example, the pusher bar 110PR may push the case unit CU laterally in the Y direction so that the case unit contacts the fence 110PF (which is positioned on the access side 401 of the loading section 110PL such that the reference position of the case unit can be formed through contact between the case unit CU and the fence 110PF). In one embodiment, the pusher bar 110PR may engage or grip the case unit CU during transport of the case unit (for example, to hold the case unit against the fence 110PF) in order to maintain the case unit CU in a predetermined spatial relationship with respect to each other and to the reference coordinate system REF of the bot 110 (Figure 6) (Figure 14, block 1130). Once the case unit is positioned, the pusher bar 110PR is withdrawn from contact with the case unit CU (for example, in the Y direction) after aligning the case unit CU with respect to the fence 110PF (Figure 14, block 1140). Approximately immediately after the pusher bar 110PR disengages from the case unit CU, one or more of the lifting axis (e.g., in the Z direction) and / or extending axis (e.g., in the Y direction) of the transfer arm 110PA are actuated approximately simultaneously with the withdrawal of the pusher bar 110PR (Figure 14, block 1150). In one embodiment, both the lifting axis and the extending axis are actuated when the pusher bar is withdrawn from contact with the case unit CU, while in other embodiments, only one of the lifting axis and / or extending axis is actuated. As can be understood, the simultaneous operation of the lifting axis and / or extending axis of the transfer arm 110PA with the withdrawal of the pusher bar 110PR, as well as the reduction in the distance the pusher travels to align the case unit CU, reduces the time required to transfer the case unit CU to and from the bot 110, and increases the processing capacity of the storage and retrieval system 100.

[0057] Referring to Figures 2A, 2B, and 12 as described herein, each bot 110 is configured to transport a pick face between the retrieval passage 130A and the transfer / delivery station TS and buffer station BS. In one embodiment, a control server 120 is configured to command the bots 110 to classify the cases in the outbound flow (also known as the order processing stream, outbound stream, or order processing) independently of the order in which the bots 110 retrieve the cases from the storage area to form the pick faces. In one embodiment, a bot control device 110C is configured to command the bots 110 to classify the cases in the outbound flow independently of the order in which the bots 110 retrieve the cases from the storage area to form the pick faces. In yet another embodiment, both the control server 120 and the bot control device 110C are configured to command the bots 110 to classify the cases in the outbound flow independently of the order in which the bots 110 take cases from the storage area to form the pick face. Thus, the control server 120 and / or the bot control device 110C are configured, at least in part, to set the outbound case flow together with the bots 110's classification of cases commonly carried by the bots 110, and separate from the order in which the bots 110 take cases from the storage area.To the extent that it can be understood, in one embodiment, each bot 100 is configured to transport pick faces between a first pick face interface station (e.g., a transfer / delivery station TS and / or buffer station BS) and a second pick face interface station (e.g., a transfer / delivery station TS and / or buffer station BS spaced apart from the first pick face interface station), and as described herein, bot 110 takes a first pick face from the first interface station, moves it back and forth on the transfer deck 130B, and positions / buffers the first pick face or at least a portion thereof at the second pick face interface position such that the second pick face interface station has a plurality of pick faces buffered on a common support / surface CS in a sequence of pick faces ordered according to a predetermined case discharge order sequence of mixed case pick faces. As described later, bot 110 is configured to transport a first pick face PCF1 having any appropriate number of case units inside from the retrieval passage 130A (or transfer station TS or buffer station BS), and to place a second pick face PCF2, which is different from the first pick face PCF1, onto a common surface CS (such as rack shelf RTS) of the transfer / delivery station TS (or buffer station BS) common to bot 110 and lift 150B. This may also be called, for illustrative purposes, the classification of the outbound flow by bots of the transfer station (and / or buffer station). Also as described later, the first and second pick faces, in one embodiment, have at least one case unit common to both the first and second pick faces.In one embodiment, as described herein, the bot 110 is configured to construct the first pick face (e.g., at least one of a plurality of pick faces) on the fly, for example, during travel from a first pick-up location in a pick-up passage 130A to the placement of a second pick face at a transfer / delivery station TS (or buffer station BS) in a multiple pick-up / placement sequence (e.g., while the bot is moving). In another embodiment, the bot 110 is configured to construct the first pick face (e.g., at least one of a plurality of pick faces placed on a common plane CS) on the fly, for example, during travel from a first pick-up location in a multiple pick-up / placement sequence to a transfer / delivery station TS (or buffer station BS) (e.g., while the bot is stationary at a second pick face interface station or the buffer of the second pick face interface station). To be understood, if a pickface is retrieved by a bot, for example, 110, from a first pickface interface station, such as a transfer station TS or buffer station BS, and placed in a second pickface interface station, such as another transfer station TS or buffer station BS, the pickface bypasses storage (for example, it is not placed in storage space 130S before being transported to the second pickface interface station). In other embodiments, at least a portion of the pickfaces retrieved from the first pickface interface station are placed in storage space 130S (for example, in a storage rack array RMA) by the bot, 110, before being transported to the second pickface interface station.In one embodiment, the pick face taken out from the receiving transfer station TS (or buffer station BS) may be the same pick face that is placed at the outbound transfer station TS (or buffer station BS) (i.e., the pick face is not disassembled during transport from the receiving transfer station TS / buffer station BS to the outbound transfer station TS / buffer station BS, and transport between the receiving and outbound stations may or may not include the placement of the pick face in the storage area).

[0058] The control device 110C of the bot 110 is configured to bring about on-the-fly construction of a first pick face (or any other pick face picked up by the bot 110). In one embodiment, the bot 110 is configured to construct a pick face, for example, by loading it onto a loading section 110PL, as described herein, and the case units / pick faces are picked up by the bot and placed in the loading section in a predetermined order or sequence. In one embodiment, the bot 110 is configured to pick up / construct a pick face PCF3 different from the first pick face PCF1 and place this different pick face PCF3 on a shelf of a transfer / delivery station TS (or buffer station BS) (such as another rack shelf RTS stacked above and below a rack shelf forming a common surface CS). The bot 110 includes case operations as described herein. The bot is configured to retrieve the first pick face PCF1, then retrieve the second pick face PCF2 from one or more case units of the rack shelf RTS (or other location such as a storage shelf in the retrieval aisle) (forming a different pick face PCF3), and place this different pick face PCF3 on the common plane CS. As can be understood, in one embodiment, the lift 150B is configured to retrieve the second pick face PCF2 from the transfer / delivery station TS. In another embodiment, the lift 150 is configured to retrieve the third pick face PCF4 from the common plane CS (such as the rack transfer shelf RTS) of the transfer / delivery station TS (or buffer station BS) as described herein, the third pick face PCF4 differs from the first and second pick faces PCF1, PCF2, and the common case is common to the first, second and third pick faces PCF1, PCF2, PCF4. As can be understood, a second interface station (such as a transfer station TS or a buffer station BS) forms a common pick-face transfer interface with respect to the lift 150, such that commonly supported pick faces are commonly retrieved by the lift 150.It should be noted that the Lift 150's ability to extract individual pick faces from different deck levels, as described above, results in a classification of pick faces along the Z processing axis.

[0059] In one embodiment of the disclosed features, as can be understood, in a multiple pick-up / placement sequence, multiple case units are transported and manipulated substantially simultaneously within the loading section 110PL (for example, to form one or more pick faces) to further increase the processing capacity of the storage and pick-up system 100 and to result in a multiple pick-up / placement sequence according to a predetermined order unloading sequence. Also referring to Figure 1, a bot receives pick-up and place-out commands from, for example, a control server 120 (and / or warehouse management system 2500), and a bot control device 110C executes these commands to form an ordered multiple pick-up. Here, the bot 110 enters the common passage 130A1 from, for example, the transport deck 130B to make a single or common path through the pick-up passage 130A1, while the bot 110 picks up two or more case units according to a predetermined order unloading sequence (Figure 15, block 1201A). In one embodiment, the operation of a case unit CU is the classification of a case unit (in other words, the removal and placement of a case unit according to a predetermined load unloading sequence), where the case is positioned on a transport arm 110PA for removal / placement of the case unit, or positioned so that the case unit in question is not moved to or remains on the transport arm 110PA while other case units are being transported to and from the transport arm 110PA. Here, a bot 110 moves through a common unloading passage 130A1 in the direction of arrow XC, stops at a predetermined storage space 130S1 according to a predetermined order unloading sequence, the bot 110 removes one or more case units from the predetermined storage space 130S1 by the common transport arm 110PA, and the placement of the case units on the common transport arm 110PA corresponds to a predetermined order unloading sequence, which is described in more detail below (for example, the case units are classified on the fly, for example, while being transported by the bot 110).

[0060] As an example of case operation on bot 110, also refer to Figures 10B-10E, case unit CUA is removed from its case unit holding position (for example, from storage space 130S of a common retrieval passage to bring about ordered multiple retrievals, and in other embodiments, from a lift interface station TS and / or a case unit buffer station BS located on the retrieval passage or transfer deck) and transferred into the loading section 110PL (Figure 15, block 1201B). Once case unit CUA is transferred into the loading section 110PL, the pusher bar 110PR may be pre-positioned adjacent to the fence 110PF so as to be positioned between case unit CUA and the fence 110PF when case unit CUA is lowered for transfer to roller 110RL (Figure 15, block 1205) (Figure 15, block 1204). The pusher bar 110PR is operated to push the case unit CUA (which is placed on the roller 110RL) in the Y direction toward the rear (e.g., rear) 402 of the loading section 110PL so that the case unit CUA contacts the alignment surface 273JS (Figure 10) of tines 273A-273E and aligns with the rear 402 of the loading section 110PL (Figure 15, block 1210).

[0061] In one embodiment, bot 110 continues to move back and forth in the same direction XC along a common retrieval passage 130A1 (for example, so that all case units in an ordered multiple retrieval are retrieved along a common path in the retrieval passage by bot 100 moving in a single direction) and stops in another predetermined storage space 130S according to a predetermined order unloading sequence. As described above, the pusher bar 110PR remains in contact with (gripping) the case unit CUA during transport of the case unit between case unit holding positions so that the case unit CUA remains in a predetermined position (and / or a predetermined position in the longitudinal direction) behind the loading section 110PL with respect to the reference coordinate system REF of bot 110 (Figure 15, block 1215). For example, to retrieve a subsequent case unit from another storage space 130S2 in the common retrieval passage 130A1, the pusher bar 110PR is moved in the Y direction to disengage case unit CUA, and the lifting and extending axes of the transfer arm 110PA are actuated to retrieve another case unit CUB from the other storage space 130S2 (or, in other embodiments, for example, the lift / transfer interface station TS and / or buffer / transfer station BS as described above) (Figure 15, block 1220). While case unit CUB is being retrieved, the pusher bar 110PR is positioned adjacent to the rear 402 of the loading section 110PL in the Y direction so as to be located between case unit CUA and the alignment surfaces 273JS of tines 273A-273E (Figure 15, block 1225). Case unit CUB is transported into the loading section and lowered / placed on roller 110RL so that case units CUA and CUB are positioned relative to each other along the Y axis (Figure 15, block 1230). Pusher bar 110PR is actuated in the Y direction to push case units CUA and CUB toward fence 110PF in order to align them forward (Figure 15, block 1234) and to grip / hold case units CUA and CUB for transport (Figure 15, block 1235).To make it clear, in one embodiment, case units CUA and CUB are arranged together in a case unit holding position, but in other embodiments, case units CUA and CUB are separated and transported to separate locations in a common case unit holding position, for example, or to different case unit holding positions, as further detailed below (Figure 15, block 1240). For example, also see Figures 7-9, a bot 110 carrying an ordered multi-extract load transports the ordered multi-extract case units to one or more interface stations TS (including buffer shelves 7000A-7000L) corresponding to discharge lifts 150B1 and 150B2.

[0062] As can be understood, in one embodiment, when bot 110 “parallel parks” within the interface station TS (Figure 7) or turns around within the peer 130BD (Figure 8), the spacing between bots moving on the high-speed bot transport path HSTP of the transport deck 130B (Figure 2A) is such that a bot interacting with the interface station TS can decelerate and turn around within the interface station TS with virtually no interference from and / or with other bots 110 moving along the transport deck 130B. In other embodiments, since the transport deck 130B is substantially open and configured for non-deterministic movement of bots 110 across and along the transport deck 130B as described above, bots moving on the transport deck may be driven around bots turning around within the interface station. If multiple retrieval case units are located in different positions on the common buffer shelves 7000A-7000L of the interface / transfer stations of lifts 150B1 and 150B2, bot 110 places the first case unit CUB (for illustrative purposes, corresponding to pick face 7 in Figure 9, and including a single case unit in this example) in the first position on buffer shelf 7000B, and the second case unit CUA (for illustrative purposes, corresponding to pick face 5 in Figure 9, and including a single case unit in this example) in the second position on buffer shelf 7000B. If multiple retrieval case units are located in a common case unit holding position, bot 110 places both case units CUA and CUB together (for example, as a pick face) in the common position on buffer shelf 7000A (for illustrative purposes, corresponding to pick face 9 in Figure 9, and including two case units in this example).

[0063] When case units CUA and CUB are separated for placement at different locations within a common case unit holding position or at different case unit holding positions (Figure 15, block 1250), case units CUA and CUB are separated from each other in the loading section 110PL. For example, the take-out head 270 of the transfer arm 110PA may be moved in the Z direction to lift case units CUA and CUB from the roller 110RL by a sufficient amount for the pusher bar 110PR to pass directly beneath the case units (Figure 16, block 1250A). Once case units CUA and CUB are lifted, the pusher bar 110PR is positioned along the Y direction so that it is located between case units CUA and CUB (see Figure 10E) (Figure 16, block 1250B). The take-out head 270 is then lowered so that case units CUA and CUB are transferred to the roller 110RL and the pusher bar is inserted between case units CUA and CUB (Figure 16, block 1250C). The pusher bar 110PR is moved in the Y direction to move case unit CUA toward the rear 402 of the loading section 110PL (for example, toward the alignment surface 273JS of tines 273A-273E or any other suitable position) (for example, to separate the case unit), while case unit CUB remains in front of the loading section 110PL adjacent to the fence 110PF (for example, shown in Figure 10C) (Figure 16, block 1250D). As can be understood, when the case unit is held toward the alignment surface 273JS of the tine during transport, the pusher bar is moved in the Y direction to move case unit CUB toward the front 401 of the loading section 110PL (for example, toward the fence 110PF or any other suitable position) (for example, to separate the case unit), while case unit CUA remains behind the loading section 110PL adjacent to the alignment surface 273JS.The pusher bar 110PR may be moved in the Y direction to realign case unit CUB with fence 110PF in order to position the case unit on tines 273A-273E for placement in the case unit holding position (Figure 16, block 1250E). As can be understood, with case unit CUA substantially positioned against the alignment surface 273JS of tines 273A-273E (e.g., of the take-out head 270), case unit CUB can be positioned in the case unit holding position substantially without interference from case unit CUA (Figure 16, block 1250F), for example, case unit CUA avoids contact with the case unit positioned in the case unit holding position. Case unit CUA is lowered / transported back into the loading section 110PL (e.g., by retracting and lowering the transport arm 110PA) (Figure 16, block 1250G). A pusher bar 110PR, pre-positioned between the alignment surface 273JS and case unit CUA, pushes case unit CUA, positioned on roller 110RL, against fence 110PF to align case unit CUA forward for placement in another case unit holding position (e.g., a different holding position from the one in which case unit CUB is positioned) (Figure 16, block 1250H). The pusher bar 110PR remains opposed to case unit CUA to grip the case unit (e.g., by the fence) during transport to the other case unit holding position (Figure 16, block 1250I). The pusher bar 110PR moves away from case unit CUA, and the transport arm is actuated to raise and extend the take-out head 270 to position case unit CUA in the other case unit holding position (Figure 16, block 1250J).

[0064] An example of a case unit transfer process of bot 110, including multiple pick-up and placement operations of case units with on-the-fly sorting of case units, for producing mixed pallet loads MPL (shown in Figure 1F) and / or for processing a predetermined order sequence of items picked up at an operator station or cell 160EP according to a predetermined order unloading sequence (for example, as shown in Figure 26 for processing a customer order) in one or more bags, totes or other containers TOT, is described with respect to Figures 9 and 11-13 according to aspects of the disclosed embodiments. For example, referring to Figure 11, a customer order may require that case unit 7 be transported to unloading lift 150B1 and case unit 5 also be transported to unloading lift 150B1 (note that in other embodiments, a customer order may require that case units transported by a common bot 110 be transported to different unloading lifts 150B1, 150B2 (Figure 9) such that the transfer of case units transported by a common bot 110 to different unloading lifts occurs in substantially the same manner as described herein). In embodiments of the embodiments disclosed herein, the discharge lift 150B1 (for example, each of the discharge lifts 150B1 and 150B2 in the storage and retrieval system / order processing system) defines a processing path or passage (also referred to as a stream) of mixed case pick faces, from the storage array to the loading filling section, where the mixed case pick faces enter and exit the processing path in substantially the same order. As can be understood, the in-and-out lifts 150A and 150B are described as lifts that reciprocate vertically, but in other embodiments, the in-and-out lifts 150A and 150B are any suitable transport modules for transporting case pick faces to and from the storage structure 130 (for example, between each pick face interface station such as a transfer station TS or buffer station BS, and each of the in-station station 160IN such as an in-cell, and each of the loading station 160UT such as a loading filling section / cell).For example, in another embodiment, the lift modules 150A, 150B are one or more vertically reciprocating lifts, any suitable automated item handling system, conveyors, bots, turntables, roller beds, or multi-level vertical conveyors (e.g., Paternoster conveyors) that operate synchronously or asynchronously. To efficiently utilize each bot 110 in the storage and retrieval system 100, a control device, such as a control server 120, determines which retrieval aisles the case units 5, 7 are located in. The control device also determines which incoming case unit ICUs should be stored in the retrieval aisles from which the case units 5, 7 (e.g., outgoing case units) are retrieved. The control device sends commands to the bots 110 on the level where the case units 5, 7 are located to retrieve one or more incoming case unit ICUs from the interface station TS of one or more lift modules 150A in substantially the same manner as described above (Figure 17, block 1400A). Bot 110 grasps a case unit ICU (Figure 17, block 1420) and transports the case unit to one or more storage spaces 130 within one or more retrieval passages 130A2 (Figure 17, block 1421), where at least one of the retrieval passages where the incoming case units are located includes one of the outgoing case units 5, 7. As can be understood, when an incoming case unit is located in a different storage location 130S, the incoming case unit is classified as described above (Figure 17, block 1425), and one or more case units are transported to a single case unit holding location such as a storage space 130S or a buffer (Figure 17, block 1430), while the untransported case units are returned to the loading section of Bot 110 for transport to another case unit holding location (Figure 17, block 1435).

[0065] As can be understood, the outgoing case units 5 and 7 are located in the same or different retrieval passages and are retrieved by one bot 110 or different bots 110, depending on the proximity of the outgoing case units and the predetermined storage locations of the incoming case units. For example, referring to Figure 11, bot 110 retrieves the incoming case unit ICU from the interface station TS of the lift module 150A (in a similar manner to that described above) for placement into retrieval passage 130A2, which is the retrieval passage where case unit 5 is located. In this example, case unit 7 is located in retrieval passage 130A1. After placement of the incoming case unit ICU, the bot continues to move along retrieval passage 130A2 in a common path to retrieve the outgoing case unit 5 (e.g., a single movement in one direction along the retrieval passage) (Figure 17, block 1400). If it is more efficient to have a single bot 110 retrieve multiple case units, the outgoing case unit 5 is aligned on the bot 110 as described above (Figure 17, block 1405), and the bot moves to the location of another case unit, such as the outgoing case unit 7 located in passage 130A1 (note that if the second outgoing case is located in a passage common to the first outgoing case, both outgoing case units are retrieved via a common path in the retrieval passage by the common transfer arm 110PA of the bot 110 (Figure 6)). The second outgoing case unit 7 is retrieved by the common transfer arm 110PA (Figure 17, block 1410), and both case units 5 and 7 are transported and placed in one or more peripheral buffer stations BS and interface stations TS of a pick-face transport system such as the lift module 150B in substantially the same manner as described above with respect to the placement of incoming case units (Figure 17, blocks 1420-1435).After each outbound case has been removed (Figure 17, block 1400), if it is more efficient to have two different bots 110 remove each of the case units 5 and 7, the case units are grasped (Figure 17, block 1420) and transported and placed to one of the peripheral buffer stations BS or interface stations TS of the outbound lift 150B as described herein (Figure 17, blocks 1421-1435). In one embodiment, if an outbound case unit such as case unit 5 is placed at the peripheral buffer station BS, a different bot 110 than the one that placed case unit 5 at the peripheral buffer station BS transports case unit 5 to the interface station TS, while in another embodiment, the same bot 110 returns to the peripheral buffer station BS to transport case unit 5 to the interface station TS. In embodiments of the embodiments disclosed herein, a buffer station BS and / or a transfer station TS (e.g., at least one pick face transfer station) commonly supports pick faces of two or more mixed cases that define a portion of the pick faces of mixed cases being discharged from a storage array / structure 130, entering a path in a sequence of pick faces ordered based on a predetermined load filling sequence. In one or more embodiments of the embodiments disclosed herein, the buffer station BS and / or the transfer station TS form a common pick face transfer interface to the discharge lift 150B1 such that the commonly supported pick faces are commonly picked up by the discharge lift 150B1. In one or more aspects of the embodiments disclosed herein, each buffer station BS and / or transfer station TS commonly supports two or more pick faces of mixed cases that define a portion of the pick faces of mixed cases being taken out of a storage array in a sequence of pick faces ordered based on a predetermined load filling sequence (see pick faces 1-4 in Figure 9 for illustrative purposes only).In one or more embodiments of the embodiments disclosed herein, a portion of the pick faces of mixed cases being retrieved from a storage array / structure 130 in an ordered sequence are defined, and the pick faces of the mixed cases, commonly supported on a buffer station BS and / or transfer station TS, are based on a sequence of ordered pick faces on another buffer station BS and / or transfer station TS of a different achievement path (see, for example, mixed cases being retrieved from a retrieval lift 150B2). In one or more embodiments of the embodiments disclosed herein, any suitable control device, such as a control device 120, communicates with the bot 110 and is configured to result in the placement of pick faces onto the buffer station BS and / or transfer station TS based on a sequence of ordered pick faces.

[0066] In one embodiment, the outgoing case unit is picked up and transported as a whole (e.g., as a pick face) by a common transport arm 110PA (Figure 6) of the bot 110. Referring again to Figure 12, a customer order may require that case unit 7 be transported to the outbound lift 150B1 and case unit 5 also be transported to the outbound lift 150B1 (note that in another embodiment, a customer order may require that case units transported by the common bot 110 be transported to different outbound lifts 150B1, 150B2 (Figure 9) so that the transport of case units transported by the common bot 110 to different outbound lifts occurs in substantially the same manner as described herein). As described above, the control unit determines which incoming case unit ICU should be stored in the pick-up passage from which case units 5, 7 (e.g., outgoing case units) are picked up. The control device sends a command to the bot 110 on the level where case units 5 and 7 are located to retrieve one or more incoming case units ICU as a whole (e.g., a pick face) from the interface station TS of the lift module 150A in substantially the same manner as described above (Figure 17, block 1400A). The bot 110 grasps the pick face PF1 (Figure 17, block 1420) and transports the pick face PF1 to the storage space 130 in the retrieval passage 130A2 (Figure 17, block 1421), while the outgoing case units 5 and 7 are located in the storage space 130S, and the pick face PF1 is placed in the storage space 130S (Figure 17, block 1430). Note that since the entire pick face has been transported to a common storage space and there are no case units left on the bot, the flow does not proceed to block 1435 in Figure 17 in this example.

[0067] After positioning the incoming pick face PF1, the bot 110 continues to move along passage 130A2 via a common path (e.g., a single inbound and outbound passage) to a storage space holding the outbound case units 5 and 7 (which are arranged adjacent to each other on storage shelves so that they can be simultaneously retrieved as the outbound pick face PF2). The bot 110 picks up the pick face PF2 using a common transfer arm 110PA (Figure 6) (Figure 17, block 1415), grasps the pick face PF2 (Figure 17, block 1420), and transports the pick face PF2 to the outbound lift 150B1 (Figure 17, block 1421). In one embodiment, the case units 5 and 7 of the pick face PF2 are arranged as a single unit in one of the peripheral buffer stations BS or interface stations TS (Figure 17, block 1430). In another embodiment, the case units 5 and 7 of the pick face are separated and aligned (in a similar manner to those described above) for placement in different locations (Figure 17, block 1425). For example, bot 110 places case unit 7 at peripheral buffer station BS (Figure 17, block 1430), returns case unit 5 to the loading area of ​​bot 110 (Figure 17, block 1435), grasps case unit 5 (Figure 17, block 1420), transports case unit 5 to interface station TS (Figure 17, block 1421), and transfers case unit 5 to interface station (Figure 17, block 1430).

[0068] In another embodiment, referring to Figure 13, the outgoing case units 5 and 7 are retrieved from different storage locations in a common passage 130A2 by a common transfer arm 110PA of the bot 110 (Figure 6). Here, the bot 110 transports one or more incoming case units ICU to one or more storage locations in the manner described above, with at least one of the incoming case units ICU located in the common retrieval passage 130A2 with the outgoing case units 5 and 7. After positioning at least one incoming case unit in a predetermined storage location 130S in the passage 130A2, the bot 110 continues to move along the common path of the retrieval passage 130A2 through the retrieval passage 130A1 and retrieves case unit 5 from storage space 130S1 in the manner described above (Figure 17, block 1400). Case unit 5 is positioned on the bot 110 behind the loading section 110PL as described above (Figure 17, block 1405). Bot 110 continues to move through the retrieval passage 130A1 along a common path of the retrieval passage, and the common transfer arm 110PA retrieves case unit 7 from the different storage space 130S2 so that both case units 7 and 5 are positioned adjacent to each other on the common transfer arm 110PA (Figure 17, block 1410). As can be understood, in one embodiment, the control device 110C is configured to result in the retrieval of case units in any appropriate order, such as the reverse order in which the case units were arranged.

[0069] In this example of multiple retrieval, the case unit holding position corresponds to the storage space 130S of the retrieval passage 130, but in other embodiments, the case unit holding position includes the loading lift modules 150A1, 150A2 (where direct transfer between the bot and the lift occurs), the interface or peripheral buffer stations TS, BS (where indirect transfer between the lift module and the bot occurs) for interacting with the loading lift modules 150A1, 150A2, and the storage space 130S (note that retrieval by the bot 110 from the interface station TS and loading lift module 150A is carried into the storage rack array in a just-in-time manner so that the case units required for a predetermined order unloading sequence are not placed in the storage space 130S but are transported substantially directly to the unloading lifts 150B1, 150B2).

[0070] Bot 110 grasps both case units 7 and 5 within the loading section 110PL in the manner described above and exits the unloading passage 130A1 (Figure 17, block 1420). Bot moves along the transport deck 130B and interacts with the unloading lift 150B1 (Figure 17, block 1421). In any suitable manner, such as aligning case unit 7 to the front of the loading section 110PL and case unit 5 to the rear of the loading section 110PL, Bot separates case units 7 and 5 within the loading section 110PL as described above (Figure 17, block 1425). Case unit 7 is transported to the peripheral buffer station BS (Figure 17, block 1430). Bot retracts the transport arm 110PA to grasp case unit 5 and return it to the loading section 110PL (Figure 17, block 1435) (Figure 17, block 1420). Case unit 5 is transported to the interface station TS of the unloading lift 150B1 (Figure 17, block 1421), positioned in front of the loading section 110PL as described above (Figure 17, block 1425), and transported to the transfer station TS as described above (Figure 17, block 1430). In other embodiments, depending on a predetermined case unit unloading sequence, the bot 110 places both case units 7, 5 in a common location / position, such as on one of the unloading lifts 150B1, 150B2. For example, a pick face 20 on shelf 7000H (Figure 9) may include both case units 7, 5 so that the bot 110 places both case units in a single location on shelf 7000H as a pick face of multiple case units. As can be understood, case units placed at buffer station BS are transported to interface station TS in one embodiment by bot 110, and in other embodiments by any suitable conveyor connecting buffer station BS to interface station TS.In one embodiment, when a case unit is transported from a buffer station BS to an interface station TS by a bot 110, this transport is a timely transport, for example, when the bot 110 moves along a transport deck on a route for another task (e.g., transporting pick faces to a storage unit, classifying pick faces, transporting pick faces from a storage unit, etc.) and moves near the buffer station BS, stops to retrieve pick faces from the buffer station BS, and transports the pick faces to the interface station TS in the process of performing other tasks.

[0071] An example of the case unit transfer process of bot 110, including multiple retrieval and placement operations of case units with on-the-fly classification of case units to create a mixed pallet load MPL (shown in Figure 1F) according to a predetermined order unloading sequence, is described with respect to Figures 9 and 24 according to an aspect of the disclosed embodiment. The transfer of pick faces with respect to Figures 9 and 24 is substantially the same as described above with respect to Figures 11-13, except in this embodiment that storage of pick faces is bypassed so that pick faces are transferred substantially directly between inbound and outbound lifts 150A, 150B1. In one embodiment, bot retrieves a first pick face 5 from a first shelf of a first pick face transfer station, such as a transfer station TS of an inbound lift 150A, and the inbound lift 150A transfers one or more pick faces / cases on the pick face transfer station (Figure 23, block 2300). Bot 110 moves along the transfer deck 130B and buffers the first pick face 5 (or part thereof) on a second shelf of a second pick face handover station, such as a transfer station TS or buffer station BS of an outbound lift 150B1 (Figure 23, block 2310). In another embodiment, the first pick face 5 (or part thereof) is buffered at the transfer station TS of the outbound lift 150B1, rather than at the buffer station BS. Bot 110 forms second pick faces 5, 7 on a second shelf, the second pick faces being different from the first pick face 5 and comprising two or more cases of an order sequence corresponding to a predetermined case outbound order sequence of a mixed case, with the first pick face 5 and the second pick faces 5, 7 having at least one case in common (Figure 23, block 2320). In one embodiment, the lift 150B1 retrieves the second pick faces 5 and 7 from a second shelf, such as a buffer station BS or a transfer station TS (Figure 23, block 2330).In one embodiment, the bot 110 forms a second pick face 5, 7 on the second shelf (e.g., a buffer station BS or a transfer station TS) on the fly while transporting the first pick face 5 between the first shelf and the second shelf. In one embodiment, the bot forms the second pick face 5, 7 while mounted on an autonomous transport vehicle. In one embodiment, the bot 110 forms the second pick face 5, 7 on the second shelf or a buffer portion of the second shelf. In one embodiment, the bot 110 places at least a portion of the first pick face to be taken from the first shelf (e.g., if the pick face 5 contains two or more cases) on a storage rack of the storage array (e.g., storage space 130S) before transporting at least a portion of the first pick face to the second shelf. In one embodiment, the second shelf forms a common pick face transfer interface for a vertically reciprocating lift, and the method further includes the common retrieval of commonly supported pick faces by the vertically reciprocating lift.

[0072] In Figure 24, bot 10 is shown as taking one case / pick face 5 from the transfer station TS of the inbound lift 150A, but in other embodiments, bot 110 takes two (or more) inbound pick faces, such as cases / pick faces 5, 7. Here, in one embodiment, bot 110 places one pick face 5 on the outbound buffer station BS (or outbound transfer station TS) and then moves to another shelf position (another outbound buffer or transfer station BS, TS or an adjacent position on the shelf of a common buffer or transfer station BS, TS) to place a second pick face 7. In one embodiment, lift 150B1 removes pick faces 5, 7 from the buffer or transfer station BS, TS as described herein. In another embodiment, bot 110 places both pick faces 5, 7 on the outbound buffer or transfer station BS, TS. Here, lift 150B1 takes one of the pick faces 5, 7 and transports pick faces 5, 7 to the outbound station 160UT. The lift 150B1 returns to the shelves of the buffer or transfer stations BS, TS and picks up the other pick faces 5, 7 for transfer to the discharge station 160UT. In yet another embodiment, the bot 110 places both pick faces 5, 7 on the shelves of the outbound buffer or transfer stations BS, TS, and the lift 150B1 picks up both pick faces 5, 7 for transfer to the discharge station 160UT. Here, the pick faces 5, 7 are unified or handled together in any suitable way to construct a mixed pallet as shown in Figure 1F.

[0073] In the examples described herein, the transfer of the case unit between the bot 110 and the lift 150 occurs passively through the interface station TS as described above. As an example of transfer, referring to Figure 18, the autonomous transport vehicle is positioned relative to the interface station TS in a manner similar to that described above with respect to the slat 1210S and / or positioning feature 130F (Figure 18, block 1800). The transport arm 110PA of the bot 110 (e.g., end effector) extends to transport the pick face to the interface station TS, such that the fingers 273A-273E of the transport arm 110PA interact with the slat 1210S of the interface station TS (Figure 18, block 1801). As can be understood and as described above, multiple pick faces may be positioned on the interface station TS for simultaneous and independent transfer to the lift 150 (e.g., multiple individual pick faces are held simultaneously on the interface station). The lift 150 is moved so that the loading devices LHD, LHDA, and LHDB are positioned adjacent to the interface station TS (Figure 18, block 1802). The loading devices LHD, LHDA, and LHDB are extended to transfer the pick faces to the lift 150, raising their pick faces away from the interface station, for example, in the manner described above with respect to Figure 4B, so that the fingers 4273 of the loading devices LHD, LHDA, and LHDB interact with the slats 1210S of the interface station TS (Figure 18, block 1803). As can be understood, the interface station TS has no moving parts, and the transfer of the pick faces between the bot 110 and the lift 150 through the interface station TS is a passive transfer. Also as can be understood, the transfer of the pick faces from the lift 150 to the bot 110 may occur in substantially the opposite manner to the manner described above with respect to Figure 18.

[0074] In one embodiment, a pick face constructed by bot 110 (for example, in the manner described above), which is to be transported (for example, placed) to an interface station TS (and / or buffer station BS), is not identical to a pick face retrieved from the interface station TS (and / or buffer station BS) by a vertical lift 150. For example, referring to Figure 9, bot 110 constructs a first pick face, including individual pick faces 7 and 5, from storage space 130S in a rack module RM (for example, Figure 2A) (Figure 19, block 1900). Bot 110 transports and places the first pick face to a shelf 7000B of the interface station TS for transport to the vertical lift 150 (Figure 19, block 1910). To make it clear that in this example the individual pick faces 5, 7 (which form, for example, the first pick face) are placed on a common shelf 7000B for illustrative purposes only, but in other embodiments the individual pick faces 5, 7 are placed on different shelves 7000A-7000F such that the pick faces placed on the shelves by the bot 110 are different from the first pick face but include at least one case unit common to the first pick face. For example the first pick face is disassembled such that a different pick face including individual pick face 5 is placed on shelf 7000B, while another different pick face including individual pick face 7 is placed on shelf 7000H, for example. A vertical lift, such as lift 150B1, retrieves the second pick face from one or more shelves 7000A-7000F of the transfer station TS (common to both the bot 110 and the vertical lift 150B1) (Figure 19, block 1920). Here, the second pickface is different from the first pickface, but includes at least one of the individual pickfaces 5, 7 such that at least one case unit is common between the first pickface and the second pickface.

[0075] Similarly, in one embodiment, pick faces transported (e.g., placed) by the receiving vertical lift 150 (see vertical lift 150A in Figure 1) to, for example, an interface station TS (and / or buffer station BS) are not identical to pick faces retrieved from the interface station TS (and / or buffer station BS) by the bot 110. In one embodiment, the control server 120 is configured to command the bot 110 to have the bot 110 perform the classification of cases in the receiving flow (which may also be called warehouse replenishment or receiving stream) at the handover station TS (and / or buffer station BS) as the bot 110 forms pick faces, independently of the order in which cases are retrieved from the receiving station by the lift 150. In one embodiment, the bot control device 110C is configured to command the bot 110 to have the bot 110 perform the classification of cases in the receiving flow at the handover station TS (and / or buffer station BS) as the bot 110 forms pick faces, independently of the order in which cases are retrieved from the receiving station by the lift 150. In yet another embodiment, both the control server 120 and the bot control device 110C are configured to instruct the bot 110 to perform case classification of the incoming flow at the handover station TS (and / or buffer station BS) as the bot 110 forms the pick face, independently of the order in which the cases are picked up from the receiving station by the lift 150. Thus, the control server 120 and / or the bot control device 110C are configured, at least in part, to set up the incoming case flow together with the bot 110's classification of cases commonly carried by the bot 110, and separate from the order in which the cases are picked up by the lift 150. For illustrative purposes, this may be referred to as the classification of cases of the incoming flow by the bot 110 at the handover station TS (and / or buffer station BS).For example, referring to Figure 9A, the first pick face is transported by the receiving conveyor 160CB from the receiving station 160IN to one or more vertical lifts 150A1, 150A2 (Figure 20, block 2000). In this example, one of the first pick faces includes a combination of individual pick faces 5, 7, while the other first pick face includes a combination of individual pick faces 20, 22. Vertical lift 150A1 places the respective first pick faces 5, 7 on shelves 7000B of interface station TS, while vertical lift 150A2 places the respective first pick faces 20, 22 of the other interface station TS on shelves 7000H on the same storage level 130L (Figure 20, block 2010). Bot 110 constructs or retrieves a second pickface from interface station TS such that the first pickfaces, which are placed on shelves 7000B, 7000H by vertical lifts 150A1, 150A2 (for example, common to both Bot 110 and each of the respective vertical lifts 150A), are different from the second pickfaces, but the second pickfaces include at least one case unit in common with the first pickfaces (Figure 20, block 2020). For example, the first pickfaces 5, 7 are disassembled so that different pickfaces, including individual pickface 5 (or individual pickface 7), are retrieved by Bot 110, and / or the other first pickfaces 20, 22 are disassembled so that different pickfaces, including individual pickface 20 (or individual pickface 22), are retrieved by Bot 110. Here, the second pickface is different from the first pickface, but includes at least one of the individual pickfaces of the first pickface, such that at least one case unit is common between the first pickface and the second pickface.As can be understood, the second pick face may be disassembled by the bot such that the pick face placed on at least one storage shelf by the bot 110 is different from the second pick face, but at least one case unit is common between the second pick face and the pick face placed on at least one storage shelf.

[0076] The unloading lifts 150B1 and 150B2 transport the ordered multiple pick-up items, which are placed on shelves 7000A to 7000L by the bot 110, to the unloading station 160UT according to a predetermined order unloading sequence. For example, referring again to Figure 9, the pick faces 1 to 22 are picked up by the lifts 150B1 and 150B2 in an ordered order so that they are transported to the unloading station 160UT in a predetermined order (indicated by the numbers associated with each case unit / pick face shown in Figure 9) necessary to form a mixed pallet load MPL (Figure 1F) and / or to fulfill a predetermined order sequence of items picked up in one or more bags, totes or other containers TOT at the operator station 160EP (for example, to fulfill a customer order). Thus, each of the interface stations TS for lifts 150B1 and 150B2 forms a buffer that holds one or more case units until they are required and removed by each of the lifts 150B1 and 150B2 to form mixed pallet loads.

[0077] In one embodiment, the storage and retrieval system 100 described herein is realized by providing a storage array RMA with rack storage spaces 130S arranged on racks along a passage 130A (Figure 25, block 2500). There is also provided with at least one transport deck 130B that is connected to each of the passages 130A in a manner that allows communication (Figure 25, block 2505). There is provided with at least one autonomous transport vehicle or bot 110 which has an extendable effector or transport arm 110PA for holding at least one pick face and moving back and forth between at least one transport deck 130B and passage 130A to retrieve and position at least one pick face into and from one of the rack storage spaces 130S (Figure 25, block 2510). The pick face transport axes X and Y of the storage array are defined by a passage 130A, at least one transport deck 130B, at least one autonomous transport vehicle 110 traveling over it, and an extendable effector 110PA, so that the pick faces are transported along the transport axes X and Y between the receiving section 160IN of the automated storage and retrieval system where pick faces are received into the storage array, and the retrieval pick faces from the storage array where they are positioned to fill with goods according to a predetermined goods filling order sequence. On-the-fly sorting of pick faces in a mixed case is achieved simultaneously with transport on at least one of the pick face transport axes X, Y by a combination of storage racks and autonomous transport vehicles 110 (Figure 25, block 2520), so that at least two or more of a pick face are taken from one or more rack storage spaces 130S and placed in one or more pick face holding positions (e.g., transport or buffer stations TS, BS) different from one or more rack storage spaces 130S, according to a predetermined load filling order sequence. In one embodiment, a control device 120 (operably connected to at least one autonomous transport vehicle as described above) manages the pick face transport axes X, Y, Z, and the pick face transport axes include multiple transport axes.As described above, the multiple pickface transport axes X, Y, and Z are oriented in at least two directions that are angled relative to each other. Also as described above, one of the multiple pickface transport axes Y is oriented in a different direction that is angled relative to another of the multiple pickface transport axes X, which is defined by the extension of the extendable effector 110PA and by the movement of the autonomous transport vehicle 110 along the retrieval passage 130A. In one embodiment, as described above, on-the-fly sorting is brought about by a combination of racks and at least one autonomous transport vehicle, simultaneously with transport on at least one of each of the multiple pickface transport axes. In one embodiment, a lift 150 defines another pickface transport axis Z of the storage array. As described herein, on-the-fly sorting of pickfaces in a mixed case is brought about by the lift 150, simultaneously with transport on other pickface transport axes, such that two or more pickfaces are retrieved from one or more deck levels and transported to a load-filling section according to a predetermined load-filling order sequence.

[0078] Referring next to Figures 21, 22A, and 22B, in one embodiment, the transfer of pick faces from the receiving station 160IN to the unloading station 160UT occurs without the transfer of pick faces by the bot 110. For example, referring to Figure 21, the conveyors 160CA and 160CB of the receiving and unloading stations 160IN and 160UT are arranged such that each lift 150 acts on both the receiving and unloading stations 160IN and 160UT. For example, both the conveyor 160CA1 of the receiving station 160IN1 and the conveyor 160CB1 of the unloading station 160UT1 are acted on by lifts 150A1 and 150B1. To make it understandable, each conveyor 160CA1, 160CB1 is located on a different level of the common lift 150A1, 150B1 (in a similar manner to that described above with respect to the shelves of the buffer and transfer stations BS, TS), so that pick faces can be taken out of conveyors 160CA1, 160CB1 at one level by a common lift 150A1, 150B1 and transferred to other conveyors 160CA1, 160CB1 at another level. Here, pick faces are transferred substantially directly from one conveyor 160CA1, 160CB1 (for example, from the receiving station 160IN1 to the discharging station 160UT1) by the lifts 150A1, 150B1, bypassing the bots 110 and storage structures 130. To make it understandable, in one embodiment, pick faces from the receiving station 160IN1 are placed on shelf buffers or transfer stations BS, TS by common lifts 150A1, 150B1 in order to sort the pick faces as described above before transferring them to the unloading conveyor 160CB1. Referring to Figures 22A and 22B, in one embodiment, the pick faces are transferred from the receiving station 160IN to the unloading station 160UT, bypassing the bots 110 and storage structures 130, through a buffer lane BL that connects the receiving conveyor 160CA to the unloading conveyor 160CB.

[0079] Referring to Figure 27, according to an aspect of the disclosed embodiment, storage spaces are provided arranged on racks along the retrieval passage (Figure 27, block 1600). A multi-level deck is also provided (Figure 27, block 1610), where at least one deck level of the multi-level deck communicates with each passage, and the multi-level deck and passage define the turning surface for an autonomous transport vehicle at each level of the multi-level deck. The racks of the multi-rack levels are accessed from their respective turning surfaces common to the multi-rack levels (Figure 27, block 1620), and the racks are arranged along at least one passage at each level of the multi-level deck. In one embodiment, the vertical pitch between the rack levels varies with respect to each section of the passage. In one embodiment, the vertical pitch between at least two rack levels in each section of the passage is related to a different vertical pitch between at least two other rack levels in another section of the passage, so that an autonomous transport vehicle can retrieve multiple items in an ordered sequence along a common passage path. In one embodiment, the vertical pitch between at least two rack levels in each aisle portion is related to another vertical pitch between at least two other rack levels in another aisle portion of each aisle, such that the vertical pitch and other vertical pitches substantially fill the vertical space between multiple deck levels with the stored items.

[0080] According to one or more embodiments of the disclosed embodiments, an automated storage and retrieval system is provided. The automated storage and retrieval system includes at least one autonomous transport vehicle, a transport deck defining a transport surface for at least one autonomous transport vehicle, at least one reciprocating lift, and a first pickface interface station and a second pickface interface station connected to the transport deck and spaced apart from each other, each pickface interface station having at least one autonomous transport vehicle on the transport deck and at least one pickface interface station so that pickfaces are transported between at least one reciprocating lift and at least one autonomous transport vehicle at each pickface interface station. Both form a pickface transfer interacting with one reciprocating lift, and at least one autonomous transport vehicle is configured to take a first pickface at a first pickface interface station, travel back and forth on a transport deck, and buffer the first pickface or at least a portion thereof at a second pickface interface station for transport by the pickface order sequence in accordance with the order sequence of pickfaces of a mixed case, so that at least a portion of the first pickface is buffered at the second pickface interface station.

[0081] According to one or more embodiments of the disclosed embodiments, at least one autonomous transport vehicle is configured such that the second pickface interface station has a plurality of pickfaces that are buffered on a common support, by buffering a first pickface or at least a portion thereof.

[0082] According to one or more embodiments of the disclosed embodiments, at least one of the plurality of pick faces of the second pick face interface station includes a case from the first pick face, which is different from the first pick face.

[0083] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle constructs at least one of a plurality of pick faces on the fly at the second pick face interface station while transporting the first pick face between the first pick face interface station and the second pick face interface station.

[0084] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle constructs at least one of a plurality of pick faces by mounting it on the autonomous transport vehicle.

[0085] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle constructs at least one of a plurality of pick faces in a second pick face interface station or in a buffer portion of a common support of the buffer of the second pick face interface station.

[0086] According to one or more embodiments of the disclosed embodiments, the first pick face is at least one of a plurality of pick faces of a second pick face interface station.

[0087] According to one or more embodiments of the disclosed embodiments, the automated storage and retrieval system comprises an access passage for an autonomous transport vehicle connected to a deck, and a storage array having storage racks arranged on multi-level shelves and distributed along the access passage for the autonomous transport vehicle.

[0088] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle is configured such that at least another portion of the first pickface retrieved from the first pickface interface station is placed on a storage rack of the storage array before being transported to the second pickface interface station.

[0089] According to one or more embodiments of the disclosed embodiments, the second pickface interface station forms a common pickface transfer interface to at least one reciprocating lift such that commonly supported pickfaces are commonly picked up by at least one reciprocating lift.

[0090] According to one or more embodiments of the disclosed embodiments, the transport deck is non-deterministic and has multiple transport lanes.

[0091] According to one or more embodiments of the disclosed embodiments, an automated storage and retrieval system is provided. The automated storage and retrieval system includes at least one autonomous transport vehicle, a transport deck defining a transport surface for at least one autonomous transport vehicle, at least one incoming pickface transport system disposed between an unloading cell and a load filling section, at least one outgoing pickface transport system disposed between an unloading cell and a load filling section, and a first pickface interface station and a second pickface interface station connected to the transport deck and spaced apart from each other, wherein at each pickface interface station, pickfaces are transported between one of the incoming pickface transport systems and one of the outgoing pickface transport systems and at least one autonomous transport vehicle. To this end, each pickface interface station forms a pickface transfer that interacts between at least one autonomous transport vehicle on the transport deck and one of each of the incoming pickface transport systems and outgoing pickface transport systems, wherein at least one autonomous transport vehicle retrieves a first pickface at the first pickface interface station and moves back and forth across the deck, and the second pickface interface station is configured to buffer the first pickface or at least a portion thereof at the second pickface interface station, such that there are multiple pickfaces buffered on a common support in the order sequence of pickfaces according to the outbound order sequence of a given case of pickfaces in a mixed case.

[0092] According to one or more embodiments of the disclosed embodiments, at least one of the plurality of pick faces of the second pick face interface station includes a case from the first pick face, which is different from the first pick face.

[0093] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle constructs at least one of a plurality of pick faces on the fly at the second pick face interface station while transporting the first pick face between the first pick face interface station and the second pick face interface station.

[0094] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle constructs at least one of a plurality of pick faces by mounting it on the autonomous transport vehicle.

[0095] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle constructs at least one of a plurality of pick faces in a second pick face interface station or in a buffer portion of a common support of the buffer of the second pick face interface station.

[0096] According to one or more embodiments of the disclosed embodiments, the first pick face is at least one of a plurality of pick faces of a second pick face interface station.

[0097] According to one or more embodiments of the disclosed embodiments, the automated storage and retrieval system comprises an access passage for an autonomous transport vehicle connected to a deck, and a storage array having storage racks arranged on multi-level shelves and distributed along the access passage for the autonomous transport vehicle.

[0098] According to one or more embodiments of the disclosed embodiments, the autonomous transport vehicle is configured such that at least another portion of the first pick face taken from the first pick face interface station is placed on a storage rack of the storage array before being transported to the second pick face interface station.

[0099] According to one or more embodiments of the disclosed embodiments, the second pickface interface station forms a common pickface transfer interface to one of the inbound pickface transfer systems and one of the outbound pickface transfer systems, such that a commonly supported pickface is commonly retrieved by one of the inbound pickface transfer systems and one of the outbound pickface transfer systems.

[0100] According to one or more embodiments of the disclosed embodiments, the transport deck is non-deterministic and has multiple transport lanes.

[0101] According to one or more embodiments of the disclosed embodiments, a method for automated storage and retrieval is provided. The method includes: retrieving a first pick face from a first shelf of a first pick face delivery station by an autonomous transport vehicle; buffering the first pick face on a second shelf of a second pick face delivery station by an autonomous transport vehicle; forming a second pick face on the second shelf, wherein the second pick face differs from the first pick face in that it comprises two or more cases in an order sequence corresponding to a predetermined case discharge order sequence of mixed cases, and the first and second pick faces form a second pick face having at least one case in common; and retrieving the second pick face from the second shelf by a reciprocating lift.

[0102] According to one or more embodiments of the disclosed embodiments, the method includes forming a second pick face on the second shelf on the fly while an autonomous transport vehicle is transporting the first pick face between the first shelf and the second shelf.

[0103] According to one or more embodiments of the disclosed embodiments, the method includes forming a second pick face by an autonomous transport vehicle, mounted on the autonomous transport vehicle.

[0104] According to one or more embodiments of the disclosed embodiments, the method includes forming a second pick face on a second shelf or on a buffer portion of the second shelf using an autonomous transport vehicle.

[0105] According to one or more embodiments of the disclosed embodiments, the method includes using an autonomous transport vehicle to place at least a portion of the first pick faces taken from a first shelf onto a storage rack of a storage array before transporting at least a portion of the first pick faces to a second shelf.

[0106] According to one or more aspects of the disclosed embodiments, a second shelf forms a common pickface transfer interface to a reciprocating lift, and the method further includes the reciprocating lift commonly picking up commonly supported pickfaces.

[0107] According to one or more embodiments of the disclosed embodiments, an automated storage and retrieval system is provided. The automated storage and retrieval system includes a storage array having rack storage spaces arranged on racks along a passageway, at least one transport deck connected to each of the passageway so as to communicate with each of the passageway, and at least one autonomous transport vehicle having an extendable effector for holding at least one pick face and being configured to travel on at least one transport deck and passageway, for positioning at least one pick face into one of the rack storage spaces and for retrieving at least one pick face from one of the rack storage spaces, wherein the passageway, at least one transport deck, at least one autonomous transport vehicle traveling on it, and the extendable effector define the pick face transport axis of the storage array, and the pick face is transported to the storage array The racks and autonomous transport vehicles are combined to provide on-the-fly sorting of pick faces of mixed cases simultaneously with transport on at least one of the pick face transport axes, between an receiving section of an automated storage and retrieval system where faces are received and a loading section of an automated storage and retrieval system where pick faces are loaded according to a predetermined loading order sequence for pick faces to be loaded. At least two or more pick faces of at least one are taken from one or more rack storage spaces and placed in one or more different pick face holding positions in one or more rack storage spaces according to a predetermined loading order sequence.

[0108] According to one or more embodiments of the disclosed embodiments, the automated storage and retrieval system comprises a control device operably connected to at least one autonomous transport vehicle and configured to manage a pickface transport axis, the pickface transport axis comprising a plurality of transport axes.

[0109] According to one or more embodiments of the disclosed embodiments, the multiple pick face transport axes are oriented in at least two directions that are angled relative to each other.

[0110] According to one or more embodiments of the disclosed embodiments, one of a plurality of pickface transport axes defined by the extension of the extendable effector is in a different direction and angled with respect to another of a plurality of pickface transport axes defined by the movement of the autonomous transport vehicle along the passage.

[0111] According to one or more embodiments of the disclosed embodiments, the rack and at least one autonomous transport vehicle are combined to provide on-the-fly sorting while transporting on at least one of each of a plurality of pick-face transport axes.

[0112] According to one or more embodiments of the disclosed embodiments, at least one transport deck comprises two or more transport decks arranged at different deck levels.

[0113] According to one or more aspects of the disclosed embodiments, the automated storage and retrieval system comprises a lift that is movably connected to each of the decks at different deck levels, the lift being configured to transport pick faces between the different deck levels, and defining a different pick face transport axis of the storage array.

[0114] According to one or more embodiments of the disclosed embodiments, the lift is configured to bring about on-the-fly sorting of pick faces of a mixed case, simultaneously with transport on other pick face transport axes, so that two or more pick faces are taken from one or more deck levels and transported to a load-filling section according to a predetermined load-filling order sequence.

[0115] According to one or more embodiments of the disclosed embodiments, on-the-fly classification is brought about simultaneously with transport on at least one of each of the multiple pickface transport axes and on each of the other transport axes of the lift.

[0116] According to one or more embodiments of the disclosed embodiments, an automated storage and retrieval system is provided. The automated storage and retrieval system includes a storage array having rack storage spaces arranged on racks along a passageway; at least one transport deck connected swiftly to each of the passageway; at least one autonomous transport vehicle having an extendable effector for holding at least one pick face and being configured to travel between at least one transport deck and the passageway, for positioning at least one pick face into one of the rack storage spaces and for retrieving at least one pick face from one of the rack storage spaces; and at least one lift connected swiftly to each transport deck and configured to transport pick faces to and from at least one transport deck, wherein the passageway, at least one transport deck, at least one autonomous transport vehicle traveling between thereon, the extendable effector and at least one lift define a pick face transport axis of the storage array, and the pick face is automatically placed into the storage array when a pick face is placed into the storage array. Racks and autonomous transport vehicles are configured to bring about on-the-fly sorting of pick faces of mixed cases on at least one pick face transport axis between the receiving section of the dynamic storage and retrieval system and the loading filling section of the automated storage and retrieval system, where pick faces are transported along a pick face transport axis between the receiving section of the dynamic storage and retrieval system and the loading filling section of the automated storage and retrieval system, where pick faces are arranged to be loaded according to a predetermined loading filling order sequence, and at least two or more of at least one pick face are taken from one or more rack storage spaces and arranged in one or more different pick face holding positions in one or more rack storage spaces according to a predetermined loading filling order sequence, and at least one lift is configured on another of at least one pick face transport axis so that two or more pick faces are taken from other decks of at least one transport deck and transported to the loading filling section according to a predetermined loading filling order sequence.It is configured to provide on-the-fly sorting of pick faces in mixed cases, with on-the-fly sorting occurring simultaneously with transport on at least one of each pick face transport axis.

[0117] According to one or more embodiments of the disclosed embodiments, the automated storage and retrieval system comprises a control device operably connected to at least one autonomous transport vehicle and at least one lift, and configured to manage the pick-face transport axis.

[0118] According to one or more embodiments of the disclosed embodiments, the pick face transport axis is oriented in at least two directions that are angled relative to each other.

[0119] According to one or more embodiments of the disclosed embodiments, one of the pickface transport axes defined by the extension of the extendable effector is in a different direction and angled with respect to another of the pickface transport axes defined by the movement of the autonomous transport vehicle along the passage.

[0120] According to one or more embodiments of the disclosed embodiments, the rack and at least one autonomous transport vehicle are combined to provide on-the-fly sorting simultaneously with transport on at least one of the pick-face transport axes.

[0121] According to one or more embodiments of the disclosed embodiments, at least one transport deck comprises two or more transport decks arranged at different deck levels, and at least one lift is configured to transport pick faces between different deck levels.

[0122] According to one or more embodiments of the disclosed embodiments, a method for automated storage and retrieval is provided. The method includes providing a storage array having rack storage spaces arranged on racks along a passageway, providing at least one transport deck connected to each of the passageway in communication with each other, providing at least one autonomous transport vehicle having an extendable effector for holding at least one pick face and moving back and forth along at least one transport deck and passageway, for positioning at least one pick face into one of the rack storage spaces and for retrieving at least one pick face from one of the rack storage spaces, and the pick face being placed in the receiving section of an automated storage and retrieval system where the pick face is placed into the storage array, and the retrieved pick face being placed in a predetermined load filling order sequence. The system includes defining a pick-face transport axis of a storage array by means of a passage, at least one transport deck, at least one autonomous transport vehicle traveling over it, and an extendable effector, so that the pick-faces are transported along the pick-face transport axis to and from a load-filling section of an automated storage and retrieval system, which is therefore arranged to fill the load, and providing on-the-fly sorting of pick-faces of a mixed case simultaneously with transport on at least one of the pick-face transport axes by a combination of racks and autonomous transport vehicles, so that at least two or more pick-faces are taken from one or more rack storage spaces and placed in one or more different pick-face holding positions in one or more rack storage spaces according to a predetermined load-filling order sequence.

[0123] According to one or more embodiments of the disclosed embodiments, the method includes managing a pickface transport axis by a control device operably connected to at least one autonomous transport vehicle, wherein the pickface transport axis includes a plurality of transport axes.

[0124] According to one or more embodiments of the disclosed embodiments, the multiple pick face transport axes are oriented in at least two directions that are angled relative to each other.

[0125] According to one or more embodiments of the disclosed embodiments, one of a plurality of pickface transport axes defined by the extension of the extendable effector is in a different direction and angled with respect to another of a plurality of pickface transport axes defined by the movement of the autonomous transport vehicle along the passage.

[0126] According to one or more embodiments of the disclosed embodiments, the method includes a combination of a rack and at least one autonomous transport vehicle to bring on-the-fly sorting simultaneously with transport on at least one of each of a plurality of pickface transport axes.

[0127] According to one or more embodiments of the disclosed embodiments, the method includes defining another pick face transport axis of a storage array by a lift which is communicated to each of at least one transport decks located at different deck levels and transports pick faces between different deck levels.

[0128] According to one or more embodiments of the disclosed embodiments, the method includes bringing on-the-fly sorting of pick faces of a mixed case by lift, simultaneously with their transport on other pick face transport axes, so that two or more pick faces are taken from one or more deck levels and transported to a load-filling section according to a predetermined load-filling order sequence.

[0129] According to one or more embodiments of the disclosed embodiments, the method includes bringing on-the-fly sorting to fruition simultaneously with transport on at least one of each of the multiple pickface transport axes and each of the other transport axes of the lift.

[0130] It should be understood that the above description is merely illustrative of the embodiments of the disclosed embodiments. Various alternatives and modifications can be devised by those skilled in the art without departing from the embodiments of the disclosed embodiments. Accordingly, the embodiments of the disclosed embodiments are intended to include all such alternatives, modifications, and variations that fall within the scope of the appended claims. Furthermore, the fact that different features are detailed in different dependent or independent claims does not mean that combinations of these features cannot be used advantageously, and such combinations remain within the scope of the embodiments of the invention.

Claims

1. An autonomous guided autonomous transport vehicle, A frame forming a loading area configured to hold at least one pick face, A lift movably mounted on the frame to move relative to the frame along the lift axis, A transfer arm supported by the lift, wherein the transfer arm is movable along a moving axis and is configured to support at least one pick face thereon, A payload alignment member is movably mounted on the frame to move relative to the frame along the alignment axis, A drive section connected to the frame, the drive section having at least one drive shaft configured to operate the lift and the transport arm while the transport vehicle is in transit, causing the transport arm to position or remove the at least one pick face, and the drive section having another drive shaft different from the at least one drive shaft to operate the payload alignment member to pre-position the at least one pick face to a payload alignment position on the frame, in substantially coincidence with at least part of the operation of the lift and the transport arm, A control device connected to the drive section, wherein the control device is configured to pre-position the payload alignment member while the transport vehicle is in transport, and An autonomous guided autonomous transport vehicle equipped with the following features.

2. The autonomous guided autonomous transport vehicle according to claim 1, wherein the other drive shaft operates the payload alignment member while the transport vehicle is transporting, so as to align the at least one pick face located in the loading area.

3. The autonomous guided autonomous transport vehicle according to claim 2, wherein the alignment of the at least one pick face performed while the transport vehicle is in transit results in an on-the-fly classification of the at least one pick face being transported by the autonomous transport vehicle so as to sort the at least one pick face being transported by the autonomous transport vehicle relative to one another in accordance with a predetermined case unloading order sequence.

4. The autonomous guided autonomous transport vehicle according to claim 1, wherein the control device commands the drive section to remove two or more pick faces from one or more first case unit holding positions and place them in one or more different second case unit holding positions according to a predetermined case discharge order sequence.

5. The autonomous guided autonomous transport vehicle according to claim 4, wherein the transport arm is common to the two or more pick faces and is configured to hold the two or more pick faces adjacent to each other.

6. The autonomous guided autonomous transport vehicle according to claim 3, wherein the payload alignment member positioned within the loading area moves across the longitudinal axis of the frame, and the control device is configured to control the combined movement of the payload alignment member and the transport arm to result in the classification of the at least one pick face transported to the loading area.

7. The autonomous guided autonomous transport vehicle according to claim 1, wherein the payload alignment member and the transport arm are each movable independently of each other.

8. The autonomous guided autonomous transport vehicle according to claim 7, wherein the control device is configured to control the drive section and cause the movement of the payload alignment member and the transport arm so that on-the-fly classification is achieved by at least one of the at least one pick face being held within the loading area while at least one of the at least one pick face is being transported to or from the loading area.

9. The autonomous guided autonomous transport vehicle according to claim 1, further comprising a loading bed within the loading area, wherein the loading bed includes a laterally positioned payload support portion extending through the opening of the payload alignment member.

10. The autonomous guided autonomous transport vehicle according to claim 9, wherein the transport arm includes a payload support tine spaced apart to engage with the laterally positioned payload support portion, and the lowered position of the payload support tine transports the at least one pick face to the laterally positioned payload support portion.

11. An autonomous guided autonomous transport vehicle, A frame forming a loading area configured to hold at least one pick face, A lift attached to the frame to move relative to the frame along the lift axis, A transfer arm supported by the lift, wherein the transfer arm is movable along a moving axis and is configured to support at least one pick face thereon, A payload alignment member is movably mounted on the frame to move relative to the frame along the alignment axis, A drive section connected to the frame, the drive section having at least one drive shaft operably connected to the transport arm to operate the transport arm while the transport vehicle is transporting, and on the fly along the lift, to bring the at least one pick face onto the transport arm to be positioned or removed along the lift, the drive section having another drive shaft different from the at least one drive shaft to operate the payload alignment member to the payload alignment position of the at least one pick face onto the frame, in substantially coincidence with the operation of at least one of the lift and the transport arm, at least in part, to pre-position the pick face, A control device connected to the drive section, wherein the control device is configured to pre-position the payload alignment member while the transport vehicle is in transport, and An autonomous guided autonomous transport vehicle equipped with the following features.

12. The autonomous guided autonomous transport vehicle according to claim 11, wherein the other drive shaft operates the payload alignment member while the transport vehicle is transporting, so as to align the at least one pick face positioned in the loading area.

13. The autonomous guided autonomous transport vehicle according to claim 11, wherein the lift is arranged to move relative to the frame along the lift axis.

14. The autonomous guided autonomous transport vehicle according to claim 11, wherein the control device commands the drive section to remove two or more pick faces from one or more first case unit holding positions and to place them in one or more different second case unit holding positions according to a predetermined case discharge order sequence.

15. The autonomous guided autonomous transport vehicle according to claim 14, wherein the transport arm is common to the two or more pick faces and is configured to hold the two or more pick faces adjacent to each other.

16. The autonomous guided autonomous transport vehicle according to claim 11, wherein the payload alignment member moves across the longitudinal axis of the frame, and the control device is configured to control the combined movement of the payload alignment member and the transport arm to result in the classification of the at least one pick face transported to the loading area.

17. The autonomous guided autonomous transport vehicle according to claim 11, wherein the payload alignment member and the transport arm are each movable independently of each other.

18. A method for transporting at least one pick face by an autonomous guided autonomous transport vehicle, wherein the method is To provide a frame for the autonomous guided autonomous transport vehicle, wherein the frame forms a loading area configured to hold at least one pick face, To provide a lift attached to the frame for moving relative to the frame along the lift axis, To provide a transfer arm supported by the lift, wherein the transfer arm is movable along a moving axis and configured to support at least one pick face thereon. To provide a payload alignment member that is movably attached to the frame in order to move relative to the frame along the alignment axis, To provide a drive section connected to the frame, wherein the drive section has at least one drive shaft operably connected to the transport arm to operate the transport arm while the transport vehicle is transporting, and on the fly along the lift, to bring the at least one pick face on the transport arm to be positioned or removed, and the drive section has another drive shaft different from the at least one drive shaft to operate the payload alignment member to the payload alignment position of the at least one pick face on the frame, in substantially coincidence with the operation of at least one of the lift and the transport arm, at least in part, to pre-position the pick face. The control device connected to the drive section provides pre-positioning of the payload alignment member while the transport vehicle is in transport mode. Methods that include...

19. The method according to claim 18, wherein the other drive shaft operates the payload alignment member while the transport vehicle is transporting, so as to align the at least one pick face positioned in the loading area.

20. The method according to claim 18, wherein the lift is arranged to move relative to the frame along the lift axis.

21. The method according to claim 18, further comprising the control device instructing the drive section to remove two or more pick faces from one or more first case unit holding positions and to place them in one or more different second case unit holding positions according to a predetermined case discharge order sequence.

22. The method according to claim 18, wherein the transfer arm and the payload alignment member are each movable independently of each other.

23. The method according to claim 22, further comprising the means that at least one of the at least one pick faces is held within the loading area while at least one of the at least one pick faces is being transported to or from the loading area, thereby resulting in on-the-fly sorting.

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