A warehouse system for storing and retrieving goods from containers.

Abstract

A product order fulfillment system for mixed product units held in a container for transport, the system comprising: a synchronous transport system forming a container transport path for transporting containers, the synchronous transport system having a container loading section arranged to communicate with an asynchronous container transport device for loading containers into the synchronous transport system; at least one container settling device configured to engage with a container transported along the container transport path and to rock the container in order to settle the mixed product units inside; and at least one container lid closing device configured to engage with the lid of a container transported along the container transport path and to close the lid, wherein the at least one container lid closing device and the at least one container settling device are connected to communicate with each other by the container transport path, and the synchronous transport system includes an intervening switch selector for controllably selecting the container transport path.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is a non - provisional application of U.S. Provisional Patent Application No. 63 / 452,749, filed on March 17, 2023, the entire disclosure of which is incorporated herein by reference and for which priority is claimed.

[0002] [Technical Field] The disclosed embodiments generally relate to material handling systems, and more specifically, to the conveyance and storage of articles within a material handling system.

Background Art

[0003] It is well recognized that the integration of automated storage and retrieval systems into the logistics chain, particularly goods - to - man systems, is highly advantageous across the efficiency and cost of the logistics chain. Conventional systems generally operate by storing product (e.g., supply) containers, where a supply container typically contains cases, packs, etc. that include common types of merchandise (also called products). The product containers can arrive on a pallet (e.g., a common supply container) or as a truck load, are depalletized or unloaded from the truck, stored in a logistics facility, and distributed throughout the storage volume of the logistics facility (e.g., in a three - dimensional array of storage racks) by an automated storage and retrieval system.

[0004] In particular, when combined product containers are desired (for example, here, any given order container may have combined / different products or product types held in a common container in cases such as direct to consumer fulfillment, or in cases of indirect fulfillment to consumers via a retail order collection point, the combination of ordered products in the order container is generated at least partially at the logistics facility before being shipped out of the logistics facility), order fulfillment from the logistics facility, conventionally, the creation of combined product containers is done by goods-to-person (goods to) automated storage and retrieval systems. Using a person-to-person configuration, an automated storage and retrieval system is brought from the storage location of the entire three-dimensional array of storage racks to the workstation by unloading product / supply containers (each containing articles of one or more products of a common product type, i.e., the articles of each product in the product container are the same or substantially similar), and manually or automatically, according to a given performance (or filling) order, goods are picked and retrieved from the various product / supply containers supplied to the given workstation by the automated storage and retrieval system, and the various picked goods (common if the given order that is combined or included is filled in this way) are placed into an order container. Such workstations may be called breakpack stations, where product containers are "unpacked" and their contents, in whole or in part, may be placed in order containers or in what are called breakpack storage containers (e.g., tote bags), for example, where the product containers are not suitable for continuously holding the remaining product items after the breakpack operation, and such remaining products (i.e., the remaining products in the "unpacked" product containers) should be returned to their storage location in a three-dimensional array of storage racks by an automated storage and retrieval system. Products placed in order containers are not ideally packaged in order containers because they are loosely placed into the containers by automation.Furthermore, after the order containers are filled, they remain open and need to be closed before being placed on storage shelves, within palletized loads, or for shipment to customers (e.g., e-commerce). [Overview of the project]

[0005] The aforementioned aspects and other features of the disclosed embodiments are described in the following description made in relation to the accompanying drawings. [Brief explanation of the drawing]

[0006] [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 schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1C] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1D] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1E] 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 1F] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 1G] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2A] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2B] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2C] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2D]This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2E] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 3A] This is a schematic diagram of a transport vehicle according to an embodiment of the disclosed model. [Figure 3B] This is a schematic diagram of a transport vehicle according to an embodiment of the disclosed model. [Figure 4] This is a schematic diagram of a product sorting and container closing station of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 5A] Figure 4 is a schematic perspective view of the product sorting device for a product sorting and container closing station according to an embodiment of the disclosed model. [Figure 5B] This is another schematic perspective view of a product setting device, partially removed for clarity, according to an embodiment of the disclosed model. [Figure 5C] This is a schematic rear view of the product setting device shown in Figure 5A, according to an embodiment of the disclosed model. [Figure 5D] This is a schematic front view of the product setting device shown in Figure 5A, according to an embodiment of the disclosed model. [Figure 5E] This is a schematic front view of the product setting device shown in Figure 5A, according to an embodiment of the disclosed model. [Figure 6A] Figure 4 is a schematic perspective view of the container closure bay of the goods sorting and container closure station according to an embodiment of the disclosed model. [Figure 6B] This is a schematic plan view of the container closure bay in Figure 6A according to an embodiment of the disclosed features. [Figure 7A] This is a schematic side view of the container closure bay in Figure 6A according to an embodiment of the disclosed model. [Figure 7B] This is a schematic end view of the container closure bay of Figure 6A according to an embodiment of the disclosed model. [Figure 8A]A series of schematic diagrams showing the induced closing motion of a container brought about by the container closing bay of FIG. 6A according to an aspect of the disclosed embodiment. [Figure 8B] A schematic diagram of the container in a partially closed configuration according to an aspect of the disclosed embodiment in FIG. 8A. [Figure 9] A series of schematic diagrams showing a part of the induced closing motion of a container brought about by the container closing bay of FIG. 6A according to an aspect of the disclosed embodiment. [Figure 10A] A schematic plan view of the container closing bay of FIG. 6A according to an aspect of the disclosed embodiment. [Figure 10B] A schematic plan view of the container closing bay of FIG. 6A according to an aspect of the disclosed embodiment. [Figure 11A] A schematic diagram of the container closing bay of the merchandise staging and container closing station of FIG. 4 according to an aspect of the disclosed embodiment. [Figure 11B] A schematic diagram of the container closing bay of the merchandise staging and container closing station of FIG. 4 according to an aspect of the disclosed embodiment. [Figure 11C] A schematic diagram of the container closing bay of the merchandise staging and container closing station of FIG. 4 according to an aspect of the disclosed embodiment. [Figure 11D] A schematic diagram of the container closing bay of the merchandise staging and container closing station of FIG. 4 according to an aspect of the disclosed embodiment. [Figure 11E] A schematic diagram of the container closing bay of the merchandise staging and container closing station of FIG. 4 according to an aspect of the disclosed embodiment. [Figure 11F] A schematic diagram of the container closing bay of the merchandise staging and container closing station of FIG. 4 according to an aspect of the disclosed embodiment. [Figure 12] An exemplary flow diagram of a method according to an aspect of the disclosed embodiment. [Figure 13] An exemplary flow diagram of a method according to an aspect of the disclosed embodiment. [Figure 14] An exemplary flow diagram of a method according to an aspect of the disclosed embodiment. [Figure 15] This is an illustrative flowchart of a method according to an embodiment of the disclosed features. [Modes for carrying out the invention]

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

[0008] In some aspects of the disclosed embodiments, the automated storage and retrieval system 100 may operate within a retail distribution center or warehouse to fulfill orders received from retailers for case units, such as those described in U.S. Patent No. 10,822,168, issued November 3, 2020, the entire disclosure of which is incorporated herein by reference. For example, a case unit is a case or unit of goods that is not stored (e.g., not included) on a tray, on a tote, or on a pallet. In other examples, a case unit is a case or unit of goods that is included in any suitable way on a tray, on a tote, in a container (such as a container for leftover goods after break-packing where the broken-down case unit structure is not suitable for transporting leftover goods as a unit), on a pallet, etc. In yet another example, a case unit is a combination of included and not included items. It should be noted that a case unit may include, for example, a unit of goods in a case (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. According to aspects of the disclosed embodiments, a transport case for a case unit (e.g., a carton, barrel, box, crate, jug, or any other suitable device for holding a case unit) may have a variable size, be used to hold a case unit during transport, and be configured to be palletized for transport. For example, when a bundle or pallet of case units arrives at a storage and retrieval system, the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same items; i.e., one pallet holds soup and another holds cereal), and when the pallet leaves the storage and retrieval system, the pallet may contain any suitable number and combination of various case units (e.g., a mixed pallet where each mixed pallet holds different types of case units; i.e., a pallet holds a combination of soup and cereal), and it should be noted that these are provided to a palletizer in a sorted arrangement for forming a mixed pallet, for example.In aspects of the disclosed embodiments, the storage and retrieval system 100 described herein may be applied to any environment in which the units are stored and retrieved.

[0009] According to aspects of the disclosed embodiments, orders of filled articles (e.g., pallets, cases, containers, product packages, individual (opened) articles, etc.) may be probabilistic (e.g., the articles to be ordered and the time at which the orders are received may be substantially random) and may be fulfilled by the automated storage and retrieval system 100 in accordance with time (e.g., sorting of ordered articles at a predetermined scheduled time prior to the time at which the orders are shipped / fulfilled or sorting of articles just in time). These probabilistic orders determine the picking order of sorted articles, such as for constructing pallet loads or pallet PALs, as described herein with respect to Figure 1E (see, for example, U.S. Patent No. 8,965,559, issued February 24, 2015, titled “Pallet Building System,” the entire disclosure of which is incorporated herein by reference). While the pallets in Figure 1E are illustrated and described as mixed case pallets, such examples also represent pallet loads having mixed cases, mixed totes, mixed packs, mixed units (or individual) per tote, etc. Here, the classified items are picked from a common storage array (for example, a storage array formed by the storage space 130S of the storage structure 130).The automated storage and retrieval system 100 brings a given order from a common storage array, regardless of the order type (e.g., pallet order, case order, pack order, mixed order, etc.), order order order, and order time, by utilizing or otherwise processing the order to the required classification level via one or more orthogonal classification echelons (e.g., those described in U.S. Patent Application No. 17 / 358,383, filed June 25, 2021, “Warehousing System for Storing and Retrieving Goods in Containers”), thereby bringing the goods to the maximum throughput for each order (e.g., received for processing by the automated storage and retrieval system 100) (e.g., the controller 120 drills down / drives down the orthogonal classification echelons to bring the desired level of classification required for a given order, i.e., case-level classification, pack-level classification, unit / individual-level classification, or a combination thereof).

[0010] According to aspects of the disclosed embodiments, the automated storage and retrieval system 100 includes one or more breakpack modules or stations 266 (see Figure 2C). The breakpack module 266 is configured to break down product containers or case units CU into breakpack product containers 264 (also referred herein to as product containers or mixed product unit containers) for order fulfillment. The breakpack product container 264 (briefly refer to Figure 8B) is a container having, for illustrative purposes only (but the container may have any suitable configuration), a bin portion 264B in which the goods are placed, and lid portions 264L1, 264L2 attached to the bin portion 264B by hinges, respectively. The lid portions 264L1 and 264L2 are interlocking lid portions, each having an upper locking portion 264F and a lower locking portion 264M, which interlock with each other in a cam manner to maintain a closed configuration when the lid portions 264L1 and 264L2 are closed. Here, the products are placed into the breakpack goods container 264 by automation (as described herein) so as to be loosely placed. These loosely placed products may protrude above the plane PL defined by the upper part 264T of the breakpack goods container 264, which may obstruct or otherwise prevent the closure of the breakpack goods container 264. The automated storage and retrieval system 100 includes at least one product setting and container closing station 155 (see, for example, Figures 1 and 2C) that receives breakpack product containers from the breakpack module 266 and brings about the setting of product BPGs within each breakpack product container 264 (i.e., by setting, move or adjust the products to reduce the empty space between products so that the products are ensured to be placed within the boundaries of the breakpack product container below the planar PL).In some embodiments, the automated storage and retrieval system 100 may include (in addition to or instead of) one or more picking modules substantially similar to those described in U.S. Patent No. 9,037,286 issued on May 19, 2015 (the entire disclosure is incorporated herein by reference), wherein the breakpack containers 264 are filled by a human or robotic operator and unloaded for transport by a container bot 110 in substantially similar manner to that described herein with respect to the breakpack module 266. Containers from each of these picking modules may also be transported to at least one product sorting and container closing station 155 in the manner described herein for product sorting and container closing.

[0011] One or more breakpack modules 266 and one or more product sorting and container closing stations 155 may be located on a common level 130L of the automated storage and retrieval system, where one or more levels of the automated storage and retrieval system 100 include at least one breakpack module 266 and at least one product sorting and container closing station 155. The (one or more) product sorting and container closing stations 155 may be (one or more) plug-and-play modules 155M (see Figure 2A) that can be connected to any suitable part of the structure of the automated storage and retrieval system 100. For example, the (one or more) product sorting and container closing stations 155 may be connected to the container transfer deck 130DC or the (one or more) picking (or pick) passage 130A of the automated storage and retrieval system 100. One or more product sorting and container closing stations 155 may be located at any suitable number of stacked storage levels of the automated storage and retrieval system 100, forming a stacked gang 155SG of product sorting and container closing stations 155 (see Figure 1G). Here, the product sorting and container closing station 155 has a synchronous transport device (as described herein (see Figure 1G)) that transports containers 264 to one or more of the at least one container sorting device 420 and at least one container lid closing device 430 of the product sorting and container closing station 155. The synchronous transport device is a ganged system with multiple grouped transport paths CTPs at different levels 130L (see also Figure 4 illustrating exemplary container transport path CTPs for any given level, where each level corresponds to its respective storage level 130L and has its respective transport path CTP).Each container transport path CTP at each of the different levels 130L directs the containers 264 at each level 130L to at least one of the following: at least one container settling device 420, at least one container lid closing device 430, and at least one of both the at least one container settling device 420 and the at least one container lid closing device 430. As described herein, each level of the grouping system has an unloading interface station 402 configured to communicate with an asynchronous container transport device (as described herein (see Figure 1G)) to unload containers 264 with their lids closed from the synchronous transport device to the asynchronous transport device. Here, the unloading interface station 402 forms a multi-level unloading section of the grouping system that is connected to the lift 150 via the asynchronous container transport device.

[0012] The automated storage and retrieval system 100 may be configured via any suitable controller (e.g., control server 120) to have selectable operating modes. In one operating mode, the automated storage and retrieval system 100 is configured to unload product cases, containers, and / or case units into a palletizer. In another operating mode, such as when one or more breakpack modules 266 are utilized, the automated storage and retrieval system 100 is configured to unpack product cases, product containers, and / or case units and unload the breakpack product containers, product cases, containers, and / or case units into a palletizer, or, in other embodiments, to reload (e.g., after unpacking) the remaining breakpack (order) containers and / or product cases, containers, and / or case units into a palletizer for later retrieval. At least one product sorting and container closing station 155 is configured to sort the products in the containers and close the containers before palletizing and / or returning them to storage.

[0013] The controller 120 is configured to bring about the operation of container bots 110 and product bots 262 (both forming at least part of an asynchronous transport system) for assembling orders of breakpack goods BPG from supply container 265 into breakpack goods containers 264 (see also, for example, Figure 2C), and the unloading of breakpack goods containers 264 via a container unloading station TS as described herein. For example, the controller 120 is configured to bring about the operation of (one or more) container bots 110 between the container storage position 130S, the breakpack operation station 140, the goods sorting and container closing station 155, and the breakpack goods containers 264 positioned along the breakpack goods transport deck 130DG. As another example, the controller 120 is configured to bring about the operation of (one or more) product bots 262 to sort the breakpack goods BPG into (one or more) corresponding breakpack goods containers 264, for example, by unit / individual level classification, by the transport of breakpack goods BPG by the product bots 262 traveling along the product transport deck 130DG. As a further example, the controller 120 is configured to cause the operation of (one or more) container bots 110 such that (one or more) container bots 110 access a corresponding breakpack product container 264 on the product transfer deck 130DG, transport the breakpack product container 264 to at least one product sorting and container closing station 155 via passage along the container transfer deck 130DC, and transport from at least one product sorting and container closing station 155 to at least one corresponding container storage position 130SB on a storage shelf at the corresponding level 130L of a multi-level storage array and a container unloading / transfer station TS.

[0014] Referring also to Figure 1E, it should be noted that when incoming bundles or pallets (for example, from a manufacturer or supplier of case units) arrive at the automated storage and retrieval system 100 for replenishment, the contents of each pallet may be uniform (for example, each pallet may hold a predetermined number of the same items, i.e., one pallet may hold soup and another may hold cereal). As can be understood, the cases of such pallet loads may be substantially similar, or in other words, homogeneous cases (e.g., similar dimensions) and may have the same SKU (otherwise, as mentioned above, the pallet may be a “rainbow” pallet with layers formed of homogeneous cases). When the pallet PAL leaves the storage and retrieval system 100, with the cases fulfilling the replenishment order, the pallet PAL may contain any appropriate number and combination of various case units CU (for example, each pallet may hold different types of case units, i.e., the pallet may hold combinations of canned soup, cereal, beverage packs, cosmetics, and household detergents). Cases assembled on a single pallet may have various dimensions and / or various SKUs. In one aspect of the disclosed embodiment, the storage and retrieval system 100 may generally be configured to include an incoming section, a storage and sorting section (where, in one aspect, storage of goods is optional), and an output section, as will be described in more detail below. As can be understood, in one aspect of the disclosed embodiment, the system 100, operating, for example, as a retail distribution center, may be responsible for receiving uniform pallet loads of cases, unpacking the pallet goods, or separating the cases from the uniform pallet loads into independent case units that are processed individually by the system, retrieving the various cases required by each order, sorting them into corresponding groups, and transporting the corresponding groups of cases to assemble into what is called a mixed case pallet load (MPL).As can also be understood, in one aspect of the disclosed embodiments, for example, a system 100 operating as a retail distribution center may play a role in receiving uniform pallet loads of cases, unpacking pallet goods, or separating cases from uniform pallet loads into independent case units that are processed individually by the system, taking out the various cases required by each order, sorting them into corresponding groups, and transporting and ordering the corresponding groups of cases in the manner described in U.S. Patent No. 9,856,083 issued January 2, 2018, the entire disclosure of which is incorporated herein by reference.

[0015] The storage and sorting section includes a multilevel automated storage system having an automated transport system that sequentially receives individual cases and supplies them to a multilevel storage array for storage in a storage area (such as storage space 130S of storage structure 130), as will be described in more detail below. The storage and sorting section also defines the outbound transport of case units from the multilevel storage array so that desired case units are individually retrieved according to commands generated according to orders entered into a warehouse management system, such as a 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, utilizing buffer stations and interface stations as described herein), sorts them, for example, in a case-level classification, 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 order (e.g., order-out sequences) may be carried out entirely or partially by either the storage and retrieval section or the outbound section, or both, the boundaries being for illustrative purposes only, and the sorting and grouping may be carried out in any number of ways. The intended result is that the loading section assembles appropriate groups of ordered cases, which may differ in SKU, dimensions, etc., into mixed case pallet loads in the manner described, for example, in U.S. Patent No. 8,965,559, issued February 24, 2015, entitled “Pallet Building System,” which is incorporated herein by reference in its entirety.

[0016] In the disclosed embodiments, the unloading section generates a pallet load with what may be called a structured architecture of mixed case stacks. The structured architecture of the pallet load described herein is representative, and in other embodiments, the pallet load may have any other suitable configuration. For example, the structured architecture may be any suitable predetermined configuration such as a truck bay load or other suitable container or load container envelope that holds structural loads. The structured architecture of the pallet load may be characterized by having several flat case layers L121-L125, L12T, as described in U.S. Patent No. 9,856,083, which is incorporated herein by reference in whole previously.

[0017] According to an aspect of the disclosed embodiment, referring again to Figure 1, the automated storage and retrieval system 100 includes a storage array having at least one elevated storage level 130L (for example, a storage structure 130 having a storage space 130S). Mixed product units are brought into the storage array in case CUs of product units of a common type for each case CU and distributed (each case brought into the system 100 holds a stock retention unit (SKU) of a common type). For example, the automated storage and retrieval system 100 includes a receiving station 160IN (including a depalletizer 160PA and / or conveyor 160CA for transporting articles (e.g., receiving supply containers) to a lift module 150A to place them into the storage level 130L of the storage structure 130).

[0018] As described herein, the automated storage and retrieval system 100 includes an automated transport system (e.g., bots, breakpack modules, product setting and container closing stations, and other suitable level transport devices described herein) with at least one asynchronous transport system for transporting cases / products at a given storage structure level 130L (e.g., level transport). For example, the automated storage and retrieval system 100 includes at least one storage level 130L having a storage passage (also referred herein as a picking passage) 130A and a transport deck (also referred herein as a container transport deck) 130DC connecting the storage passage 130A. At least one breakpack station 140 is connected so as to be able to communicate with the transport deck 130DC. At least one goods sorting and container closing station 155 is connected to a transport deck 130DC via an asynchronous transport system (as described herein), and at least one autonomous guide vehicle (also referred to herein as a container bot) 262 (for example, of the asynchronous transport system) is configured to travel along the transport deck 130DC (as described herein) and transport goods containers 264 having break-pack goods BPG inside from at least one break-pack station 140 to at least one goods sorting and container closing station 155.

[0019] As described herein, the storage and retrieval system 100 includes non-deterministic container bots 110 that move along one or more physical paths of the storage and retrieval system to provide at least one level of asynchronousness. At least another level of asynchronousness is provided (as described herein) such that, for example, the number of positions holding cases / products is greater than the number of bots transporting cases / products. At least one lift 150 is provided for transporting cases / products between storage levels (e.g., between level transporters). At least one lift 150B is connected to the storage array, as described herein, to automatically retrieve and unload product units distributed to case CUs in a common area of ​​at least one elevated storage level 130L of the storage array (e.g., storage position 130S of each storage level 130L) from the storage array. Unloaded product units are one or more mixed and unified product units in mixed and packed groups and in mixed cases. As an example, the automated storage and retrieval system 100 includes unloading stations 160UT and 160EC (including a palletizer 160PB, operator station 160EP and / or conveyor 160CB) for transporting goods (e.g., outbound supply containers and filled breakpack goods (order) containers) from the lift module 150B for retrieval (e.g., to a palletizer (for palletizer loads) or to a truck (for truck loads). Here, unloading station 160EC is an individual fulfillment (or e-commerce) unloading station, where, for example, filled breakpack goods (order) containers containing single goods and / or small bundles of goods are transported to fulfill individual fulfillment orders (such as orders placed by consumers over the internet). Unloading station 160UT is generally a commercial unloading station where a large number of goods are provided on pallets to fulfill orders from commercial entities (e.g., a retail store, warehouse club, restaurant, etc.).As can be understood, the automated storage and retrieval system 100 includes both a commercial retrieval station 160UT and an individual performance retrieval station 160EC, while in other embodiments it includes one or more of the commercial retrieval station 160UT and the individual performance retrieval station 160EC.

[0020] The automated storage and retrieval system 100 also includes an inbound vertical lift module 150A and an outbound vertical lift module 150B (generally referred to as the lift module 150; although an inbound lift module and an outbound lift module are shown, it should be noted that a single lift module may be used to bring in and retrieve case units from the storage structure), a storage structure 130 (which may have at least one elevated storage level as described above and, in some embodiments, form a multi-level storage array), and at least one autonomous container transport vehicle 110 (referred to herein as a “container bot” or “autonomous guided vehicle” and forming at least part of an asynchronous transport system for level transport), which may be constrained to each storage level and are separate from the transport deck 130DC on which they move. It should be noted that the depalletizer 160PA may be configured to remove case units from pallets so that the inbound station 160IN can transport the items to the lift module 150 for loading into the storage structure 130. The palletizer 160PB may be configured to place articles removed from the storage structure 130 onto a pallet PAL (Figure 1E) for transport. As used herein, the lift module 150, the storage structure 130, and the container bot 110 may together be referred herein to the above-described multi-level automated storage system (storage and sorting section), in which each throughput axis has essential "on-the-fly" sorting (e.g., sorting of case units while they are being transported) so that sorting and throughput of case units are performed substantially simultaneously without a dedicated sorting machine, such as the one described herein by reference in whole earlier in U.S. Patent No. 9,856,083.

[0021] Referring also to Figures 1, 1F, 2A, and 2C, the storage structure 130 may include (one or more) container autonomous transport travel loops 233, 233A (formed, for example, on and along the container transport deck 130DC) located at each level of the storage structure 130. It should be noted that lifts 150 are connected to the container transport deck 130DC via transport stations TS (also referred herein as container receiving stations when lift 150 is an inbound lift 150A or container unloading stations when lift 150 is an outbound lift 150B), and each lift is configured to lift one or both of supply containers 265 (empty or filled) (see Figure 2C) and break-pack goods containers 264 (empty or filled) (see Figure 2C) to and from at least one elevated storage level 130L of the storage structure 130. Container storage positions (or spaces) 130S are arranged circumferentially along the container transport deck 130DC. For example, multiple storage rack modules RM configured in a high-density three-dimensional rack array RMA are accessible by the storage level or deck level 130L. As used herein, the term “high-density three-dimensional rack array” refers to a three-dimensional rack array RMA having non-deterministic open shelves distributed along a picking aisle 130A, where, in some embodiments, multiple stacked shelves are accessible from the moving surface or picking aisle level of a common picking aisle, as described in U.S. Patent No. 9,856,083, which is incorporated herein by reference in its entirety.

[0022] Each storage level 130L includes pick-face storage / hand-off spaces 130S (hereinafter referred to as storage spaces 130S or container storage locations 130S) arranged circumferentially along the container transfer deck 130DC. At least one of the storage locations 130S is a supply container storage location 130SS, and another container storage location is a break-pack goods (or order) container storage location 130SB. In one embodiment, the storage spaces 130S are formed by rack modules RM, where the rack modules include shelves arranged along a storage or picking aisle 130A (connected to the container transfer deck 130DC) that extend linearly through, for example, a rack module array RMA and provide access for container bots 110 to the storage spaces 130S and the transfer deck 130B. In one embodiment, the shelves of the rack modules RM are arranged as multi-level shelves distributed along the picking aisle 130A. To be understood, the container bot 110 travels along the picking passage 130A and the container transfer deck 130DC through their respective storage levels 130L to transfer case units between any of the storage spaces 130S of the storage structure 130 and any of the lift modules 150 (for example, each container bot 110 has access to each storage space 130S at each level and each lift module 150 at each storage level 130L). The transfer decks 130B are arranged at various levels (corresponding to each level 130L of the storage and retrieval system) that can be stacked on top of each other or staggered horizontally, such as having one container transfer deck 130DC at one end or side RMAE1 of the storage rack array RMA, or at several ends or sides RMAE1, RMAE2 of the storage rack array RMA, as described in U.S. Patent No. 10,822,168 issued on November 3, 2020, the entire disclosure of which is incorporated herein by reference.

[0023] The container transfer deck 130DC is substantially open and configured for the non-deterministic passage of container bots 110 along multiple travel lanes that cross and along the transfer deck 130B. As described in U.S. Patent No. 10,556,743, issued on 11 February 2020 and U.S. Patent Application No. 15 / 671,591 (the entire disclosure is incorporated herein by reference), the multiple travel lanes may be configured to provide multiple access routes or paths to each storage location 130S (e.g., pick faces, case units, containers, or other articles stored on the storage shelves of rack module RM) so that container bots 110 can reach each storage location using a secondary route, for example, if the primary route to the storage location is blocked. As can be understood, one or more transfer decks 130B at each storage level 130L communicate with each of the picking passages 130A at their respective storage levels 130L. The container bot 110 travels bidirectionally between the (one or more) container transfer decks 130DC and the picking passage 130A at each storage level 130L, so as to travel along the picking passage, and accesses the storage space 130S arranged on rack shelves along each of the picking passages 130A (for example, as the container bot 110 travels through each picking passage 130A, it may have different faces, for example, seeing Figure 3A, with drive wheels 202 leading in the direction of travel or drive wheels following in the direction of travel, so as to access the storage space 130S distributed on both sides of each passage). As described above, the (one or more) container transfer decks 130DC also provide the container bot 110 with access to each of the lifts 150 at each storage level 130L, where the lifts 150 supply and retrieve case units to and from each storage level 130L, and the container bot 110 brings about the transfer of case units between the lifts 150 and the storage space 130S.

[0024] 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, which consist of a three-dimensional array RMA in which racks are arranged in a passage 130A. The passage 130A is configured for the travel of container bots 110 within the passage 130A. The container transport deck 130DC has a non-deterministic transport surface on which the container bots 110 travel, where the non-deterministic transport surface (also referred to herein as the deck surface) 130BS has a plurality of travel lanes (e.g., one or more juxtaposed travel lanes (e.g., high-speed bot travel path HSTP)) for the travel of container bots 110 along (one or more) container autonomous transport travel loops 233, 233A formed by the container transport deck 130DC, where the plurality of travel lanes connect the passage 130A. The container autonomous transport travel loop 233A provides the container bot 110 with random access to any and each picking passage 130A at each level 130L of the storage structure 130, and random access to any and each lift 150A, 150B. At least one of the multiple travel lanes has a travel direction opposite to the direction of another travel lane of the multiple travel lanes (to form the container autonomous transport travel loop 233).

[0025] The storage and retrieval system 100 may include one or more bypass passages 132 that run substantially across the picking passages 130 to allow container bots 110 to move between the picking passages 130 instead of traveling through the container transport decks 130DC, 130DC2. The bypass passages 132 may be substantially similar to the travel lanes of the container transport decks 130DC, 130DC2 as described herein and may allow bidirectional or unidirectional travel of container bots through the bypass passages 132. The bypass passages 132 may provide one or more lanes for container bot movement, where each lane has a floor and appropriate guides for guiding the bots along the bypass passages 132 in a manner similar to that described herein with respect to the transport decks 130DC, 130DC2. In other embodiments, the bypass passages 132 may have any suitable configuration to allow container bots 110 to travel between the picking passages 130. While the bypass passage 132 is shown in relation to a storage and retrieval system having transfer decks 130DC, 130DC2 located at opposite ends of the storage structure, it should be noted that in other embodiments, a storage and retrieval system 100 having only one transfer deck may also include one or more bypass passages 132.

[0026] As described herein, one or more break pack modules 266 and / or product sorting and container closing stations 155 may be located in (one or more) picking passages 130A. For example, a break pack module 266AL may be located on the side of a container transport deck 130DC where the picking passages 130A are located, and one or more picking passages 130A extend into the break pack module 266AL to form (one or more) loading surfaces 266RS of container bots. For example, a product sorting and container closing station 155AL may be located on the side of a container transport deck 130DC where the picking passages 130A are located, and one or more picking passages 130A extend into the product sorting and container closing station 155AL to form (one or more) loading surfaces 155RS of container bots. If container bot 110A delivers supply container 265 to breakpack module 266AL or delivers breakpack container 264 to product sorting and container closing station 155AL, and a picking passage 133 extending to the breakpack module or a picking passage 134 extending to product sorting and container closing station 155AL is blocked by container bot 110D, the bypass passage 132 may be used to provide a secondary or alternative route for container bot 110 to transport supply container 265 to breakpack module 266AL or breakpack container 264 to product sorting and container closing station 155AL.

[0027] It should be noted that the storage and retrieval systems shown and described herein have only exemplary configurations, and in other embodiments, any suitable configurations and components may be used for storing and retrieving the articles described herein. For example, in other embodiments, the storage and retrieval system may have any suitable number of storage sections, any suitable number of transport decks, any suitable number of breakpack modules, and corresponding loading / unloading stations.

[0028] As can be understood, the juxtaposed travel lanes are juxtaposed along a common non-deterministic transport surface 130BS between opposing sides 130BD1, 130BD2 of the container transport deck 130DC. As illustrated in Figure 2A, in one embodiment, the passage 130A is joined to the container transport deck 130DC at one side 130BD2 of the container transport deck 130DC, while in other embodiments, the passage is joined to one or more sides 130BD1, 130BD2 of the container transport deck 130DC in a manner substantially similar to that described in U.S. Patent No. 10,822,168 issued November 3, 2020, which is incorporated herein by reference in its entirety. As will be described in more detail below, the other side 130BD1 of the container transfer deck 130DC may include deck storage racks (e.g., interface station (also called transfer station) TS and buffer station BS) distributed along the other side 130BD1 of the container transfer deck 130DC so that at least one portion of the transfer deck is interposed between the deck storage racks (e.g., buffer station BS or transfer station TS) and the passage 130A. The deck storage racks are arranged along the other side 130BD1 of the container transfer deck 130DC so as to communicate with the container bots 110 from the container transfer deck 130DC and the lift module 150 (for example, the deck storage racks are accessed by the container bots 110 from the container transfer deck 130DC and are accessed by the lift 150 to pick and position the pick faces so that the pick faces are transferred between the container bots 110 and the deck storage racks and between the deck storage racks and the lift 150, and thus between the container bots 110 and the lift 150).

[0029] Referring again to Figure 1, each storage level 130L may also include a charging station 130C for charging the onboard power supply of the container bot 110 in that storage level 130L, such as those described in U.S. Patent Application No. 14 / 209,086 filed March 13, 2014 and U.S. Patent No. 9,082,112 issued July 14, 2015, the entire disclosure of which is incorporated herein by reference.

[0030] Referring to Figures 1, 2A, and 2C, as described above, the automated storage and retrieval system 100 includes one or more breakpack modules 266. In one embodiment, each breakpack module 266 has a container bot mounting surface 266RS that forms a portion 130DCP of the container transfer deck 130DC, where the mounting surface 2666RS is substantially similar to a portion of the container transfer deck 130DC; in other embodiments, the container bot mounting surface 266RS may be substantially similar to a portion of the picking aisle 130A. For simplicity of explanation, embodiments of the disclosed embodiments refer to the container bot mounting surface 266RS within the breakpack module 266 as part of the container transfer deck 130DC. In embodiments where the bot loading surface 266RS is formed by (or an extension of) a portion of the container transport deck 130DC, a single-path transport loop is exemplified in Figure 2C on the container transport deck 130D, and it should be noted that in other embodiments, the transport loop of the breakpack module 266 may be a multi-lane transport loop substantially similar to the container transport deck exemplified in Figure 2A. For example, referring to Figure 2E, the container bot travel surface 266RS is an open, non-deterministic travel surface having multiple travel inbound and outbound lanes. For example, there are multiple inbound travel lanes TL1, TL2, where travel lane TL2 is a bypass lane for moving around obstacles on travel lane TL1 (or vice versa). Multiple outbound travel lanes TL3, TL4, TL5 may also be present. Here, travel lane TL5 defines column lane 130QL (Figure 2C) for container bots 110 at the Break Pack product interface 263, while travel lanes TL4 and TL5 may be used for exits from the Break Pack module 266, with travel lane TL5 being a bypass for moving around obstacles on travel lane TL4 (or vice versa).

[0031] Each BreakPack module 266 includes a BreakPack autonomous transport travel loop 234 (see exemplary BreakPack autonomous transport travel loops 234A-234E formed on and along the product deck or product transfer deck 130DG), at least one BreakPack operating station 140, and a BreakPack product interface 263 located between the product transfer deck 130DG and the container transfer deck 130DC, interface them together. For illustrative purposes only, the product deck 130DG is illustrated as having three travel lanes forming (variable-length) travel loops 234A-234E, but in other embodiments, the product deck may have any number of travel lanes that form any number of BreakPack autonomous transport travel loops 234. Each breakpack module 266 can be nondeterministically connected to the automated storage and retrieval system 100 in any suitable way (for example, to form part thereof) (for example, a breakpack module 266 can be connected to the automated storage and retrieval system 100 at any suitable location on one or more ends 130BE1, 130BE2, etc., or can be positioned in the middle between two ends 130BE1, 130BE2 in place of the picking passage 130 (and storage location), etc., or at any other suitable location). Although the breakpack modules 266 are nondeterministically connected to the structure of the automated storage and retrieval system 100, each component of the breakpack module 166 is independent of the components of the automated storage and retrieval system (for example, self-contained as a unit) and / or is independently automated in the guidance and movement of bots (for example, product bots 262), thereby the interface between the components of the breakpack module 266 and the components of the automated storage and retrieval system 100 is nondeterministic.

[0032] One or more breakpack modules 266 can be connected to the structure of the automated storage and retrieval system 100 at any suitable location and at any suitable level 130L. For example, as described above, the breakpack modules 266 can be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC (for example, in place of the storage rack module RM / picking aisle 130A or lifts 150A, 150B, or as an extension of one or more picking aisles 130A), or at one or more sides 130BD1, 130BD2 of the container transfer deck 130DC. Each of the breakpack modules 266 is a plug-and-play module integrated with (or otherwise connected to) the container transfer deck 130DC so that the container transfer deck 130DC is connected in a manner that allows it to communicate with the container bot loading surface 266RS. In one embodiment, the container transfer deck 130DC extends into the breakpack module to form a container bot mounting surface 266RS (for example, the breakpack module forms a modular portion of the container transfer deck 130DC) so that the container bot 110 travels through the breakpack module 266 along the non-deterministic container transfer deck 130DC or moves in and out of it, and at least one of the multiple travel lanes of the container transfer deck 130DC defines a column lane 130QL (Figure 2C) for the container bot 110 in the breakpack product interface 263. In another embodiment, the container bot mounting surface 266RS includes a rail 1200S (see Figure 1D) extending from the container transport deck 130DC in a manner similar to that of the picking passage 130A, thereby allowing the container bot 110 to travel along the rail 1200S through or into and out of the breakpack module 266, with the rail 1200S defining a column lane 130QL (Figure 2C) for the container bot 110 in the breakpack goods interface 263.It should be noted that if the container bot loading surface 266RS is formed by rails 1200S, the loading surface may include a non-deterministic turning area 1200UTA (similar to an open non-deterministic container transport deck 130DC) where the container bot 110 changes direction and moves between different travel sections (e.g., inbound and outbound) of the breakpack goods autonomous transport travel loop 234. As shown in Figure 2C, the container bot travel surface 266RS of the Break Pack module 266 forms a travel loop 233 around which the container bot 110 travels, transporting supply containers (e.g., case units, pick faces, remaining containers, etc.) between storage position 130S and Break Pack operation station 140 (and / or vice versa) and Break Pack product containers (also called Break Pack containers) 264 between Break Pack product interface 263 and Break Pack product container storage position 130SB or lift 150A (and / or vice versa), respectively, along the travel loop 233 of the container bot travel surface 266RS.

[0033] The product transfer deck 130DG forms a product autonomous transport travel loop 234 located at storage level 130L. The product transfer deck 130DG is separate from the travel loop 233 formed by the container bot travel surface 266RS and has a breakpack product interface 263 that connects the respective edges of the container autonomous transport travel loop 233 of the container transfer deck 130DC and the breakpack product autonomous transport travel loop 234 of the product transfer deck 130DG. The autonomous product transport travel loops 234 formed by the product transport deck 130DG are located on the deck surface 130DGS of the deck (e.g., product transport deck 130DG) at each storage level 130L, and the (one or more) breakpack product autonomous transport travel loops 234 of the product transport deck 130DG are located on different deck surfaces 130DGS of the deck (e.g., product transport deck 130DG), separate from the deck surface 130BS of the container bot travel surface 266RS (formed by the container transport deck 130DC and / or rail 1200S) where the container autonomous transport travel loops 233 are located. The breakpack product autonomous transport travel loops 234 formed by the product transport deck 130DG (and therefore the product travel deck 130DG) are located to constrain at least one autonomous breakpack product transport vehicle (also called a product bot or product transport vehicle) 262 to each storage level 130L. At least one product bot 262 is positioned or otherwise configured to transport one or more breakpack product BPGs (e.g., packs or units unpacked from supply containers in pack level classification / units unpacked from packs in individual level classification) between the breakpack operation station 140 and the breakpack product interface 263 along a breakpack product autonomous transport travel loop 234 formed by the product transport deck 130DG. One or more container bots 110 are also configured to autonomously pick and place breakpack product containers 264 at the breakpack product interface 263, as described herein.The breakpack merchandise interface 263 may be substantially similar to one or more of the transfer stations TS and buffer stations BS described herein, and may include a non-deterministic surface (similar to the non-deterministic surface of the rack storage space 130S described herein), on which a breakpack merchandise container 264 is placed to form a non-deterministic interface between the merchandise transfer deck 130DG and the container transfer deck 130DC.

[0034] In one embodiment, the goods transfer deck 130DG facilitates a decanting process in which goods are picked from one container (such as a supply container 265 or any other suitable standardized container 265S) at the Break Pack operating station 140 and integrated with goods (generally of the same type) in another (e.g., outgoing, as described below) supply container 265 or standardized container 265S at the Break Pack goods interface 263, and the other supply container 265 or standardized container 265S is returned to storage. Generally, a supply container 265 entering the Break Pack module 266 is picked until empty, but only some (but not all) of the goods from the incoming supply container may be decanted. Here, what is called an outgoing (i.e., outgoing from Break Pack module 266) container 265 or standardized container 265S (tote, tray, etc.) may also be placed on the Break Pack goods interface 263 by (one or more) container bots 110 in a manner similar to the method described herein with respect to the Break Pack goods container 264 in order to facilitate the decanting process. In the decanting process, goods are taken out of supply containers 265 (which may be the original product / (one or more) product case packaging) at the breakpack operation station 140 and consolidated into outbound supply containers 265 or standardized containers 265S located on the breakpack product interface 263 (for example, containing the same type of goods as those taken out at the breakpack operation station 140). The storage density of the automated storage and retrieval system 100 can be increased as the supply containers 265 stored in the storage racks can be kept in a substantially "full" state (rather than having multiple containers that are not full with the same type of goods) by consolidating the same type of goods from multiple supply containers 265 to fewer supply containers 265 (which are then returned to storage by (one or more) container bots 110).In some embodiments, the decanted goods (in standardized containers or outbound supply containers) are unloaded from the storage and retrieval system 100 via a lift 150 and palletized as part of a pallet load (at an unloading station 160UT, etc.) or shipped individually (at an unloading station 160EC, etc.).

[0035] The product bot 262 may be any suitable type of autonomously guided bot having a payload configured to hold breakpack goods rather than product containers (e.g., case units, pick faces, etc.). Each product bot 262 has a payload holder configured not to resemble the payload hold of the container bot 110. The product bots 262 are configured to move autonomously and unconstrained along and across the breakpack goods autonomous transport travel loop 234 formed by the product deck 130DG. The product bots 262 are configured to automatically retrieve one or more breakpack goods BPGs (taken from the breakpack operating station 140) from the product bot 262 to the breakpack goods container 264 at the breakpack goods interface 263. A suitable example of a product bot 262 is manufactured by Tompkins International of Raleigh, North Carolina (USA) (see, for example, U.S. Patent No. 10,248,112 issued 2 April 2019). The (one or more) Breakpack Merchandise Autonomous Transport Travel Loop 234 formed by the Merchandise Deck 130DG has a plurality of travel lanes (see Figure 2C) for the movement of Merchandise Bots 262 along the (one or more) Breakpack Merchandise Autonomous Transport Travel Loop 234 formed by the Merchandise Deck 130DG (see, for example, travel loops 234A to 234E). As stated herein, the three travel lanes are illustrated for illustrative purposes only, and in other embodiments, there may be more or fewer travel lanes than three. At least one of the plurality of travel lanes is a pass-through lane for the movement of Merchandise Bots 262 to pass obstacles on another travel lane of the plurality of travel lanes in a manner similar to the method described herein with respect to the plurality of travel lanes of the Container Transport Deck 130DC. The (one or more) Breakpack Merchandise Autonomous Transport Travel Loop 234 provides Merchandise Bots 262 with random access to any and each of the Breakpack Merchandise Interface Positions 263L of the Breakpack Merchandise Interface 263.

[0036] One or more portions of the goods transport deck 130DG (such as adjacent to the breakpack goods interface position 263L) can be secured in one or more embodiments to provide an exit (or off) ramp from the travel loops 234A-234E or an entrance (or on) ramp to the travel loops 234A-234E (see also Figure 2D) to or from the breakpack goods BPG to (one or more) breakpack goods containers 264 (or supply containers 265, 265S) at the breakpack goods interface position 263L. The exit ramps (referred to herein as ramps 222, 222C, 222R) are described herein, but it should be understood that the entrance ramps are substantially opposite in direction to the exit ramps 222, 222C, 222R (for example, providing access to the travel loops rather than access from the travel loops). For example, depending on the motion characteristics (velocity, direction, etc.) and location (e.g., near a corner of the product transfer deck 130DG, away from a corner of the product transfer deck 130DG, etc.) of the bot 110 at the (specified) break pack product interface location 263L accessed by the product bot 262, one or more ramps 222, 222C, 333R are provided. For illustrative purposes only, ramp 222 is a general description of an on / off ramp that can be located anywhere on the product transfer deck 130DG and may have any suitable length. Ramp 222C is located at a corner of the product transfer deck 130DG. Ramp 222R is a “rolling” ramp that moves along the path of the product bot 262 traveling along ramp 222R.

[0037] Ramps 222, 222C, and 222R (both on and off ramps) can be temporarily "closed" from general access by product bots 262 (for example, only certain product bots delivering breakpack products to / from breakpack product interface locations 263L within the area designated by ramps 222, 222C, and 222R may have access to their respective on and off ramps). Generally, ramps 222, 222C, and 222R provide passages between the through lanes and designated breakpack product interface locations 263L. Each ramp 222, 222C, and 222R can be bidirectional (for example, if an product bot 2662 enters the ramp, travels in one direction along the ramp to pick or place breakpack products BPG, and then travels in the opposite direction along the ramp to exit the ramp). In another embodiment, the ramps may be “corresponding flow ramps” where travel along ramps 222, 222C, and 222R is generally in the opposite direction to the travel direction around one or more travel loops 234 (for example, a commodity bot 262 exits a travel loop and travels substantially in the opposite direction along ramps 222, 222C, and 222R). If ramps 222, 222C, and 222R are off ramps, they may terminate at a designated breakpack commodity interface position 263L. Similarly, if ramps 222, 222C, and 222R are on ramps, they may begin at a designated breakpack commodity interface position 263L. As described above, ramps 222, 222C, and 222R can be located anywhere on the merchandise transport deck 130DG, such that the ramp entry position varies in what is called a parking lane (for example, a lane or part of a travel loop where a merchandise bot stops to pick or place breakpack merchandise BPGs), based on one or more of the bot's motion characteristics and positions at the available breakpack merchandise interface positions 263L.While the reversals of the product bots 262 to and from ramps 222, 222C, and 222R are exemplified as substantially 90° reversals, it should be noted that in other embodiments, the reversals may have an S-shape similar to that described in U.S. Patent Application No. 16 / 144,668, filed September 27, 2018, entitled “Storage and Retrieval System,” the entire disclosure of which is incorporated herein by reference.

[0038] Ramps 222, 222C, and 222R may be dynamically created and brought forth such that the ramp "rolls" along an initial ramp length generated from the entry of a product bot with an appropriate clearance to avoid collision with the product bot (e.g., a "rolling" ramp such as ramp 222R). In one or more embodiments, ramps 222, 222C, and 222R are initiated (at bot entry) when the ramp to a designated breakpack product interface position 263L is "blocked" (or otherwise obstructed) by an active product bot 262 / active breakpack product interface position 263L, but the blockage is expected to be cleared before the product bot 262 traveling along the ramp reaches the obstruction. In one or more embodiments, if the blockage to ramps 222, 222C, and 222R is cleared, ramps 222, 222C, and 222R are extended to a designated breakpack product interface position 263L; however, if the blockage is not cleared, product bots 262 traveling along ramps 222, 222C, and 222R are reoriented, for example, to a through lane, and a new ramp is calculated / determined so that product bots 262 can position breakpack product BPGs at a designated breakpack product interface position 263L or another designated breakpack product interface position 263L.

[0039] See also Figure 13, the breakpack operating station 140 is configured so that one or more breakpack goods BPGs are unpacked from the supply container 265 at the breakpack operating station 140, and at least one goods bot 262 is configured so that one or more breakpack goods BPGs are loaded at the breakpack operating station 140. The breakpack operating station 140 includes a support surface 140S for any suitable supply container 265. In one embodiment, the support surface 140S is a non-deterministic surface substantially similar to that of a storage rack described herein and includes slats 1210S that form the support surface 140S. In other embodiments, the support surface 140S may be a non-deterministic roller conveyor (powered or unpowered) having rollers 140RL having a configuration similar to the rollers 110RL of the container bot 110 described herein (see Figures 4A and 4B), so that the tines 273A-273E of the picking head 270 of the container bot 110 (Figures 4A and 4B) engage with the rollers of the roller conveyor to position (or pick) the supply containers 265 onto (or from) the support surface 140S. Here, the container bot 110 is configured to autonomously transport (one or more) supply containers 265 from the container bot 110 to the breakpack operation station 140 (to the support surface 140S, etc.) in the manner described herein. The support surface 140S may be configured such that, once the supply container 265 is positioned by the container bot 110, the supply container 265 moves along the support surface 140S toward the operator 141 (e.g., a human operator or any suitable robotic operator (e.g., articulated arm, gantry, etc.)) for picking breakpack goods BPG from the supply container 265 in any suitable way that brings about one or more pack-level classifications of goods or unit / individual-level classifications of goods, and for placing the picked breakpack goods into one or more standardized containers 265S (totes, trays, etc.) and breakpack goods containers 264 positioned in the operator staging area 140A.The supply container 265 may be moved along the support surface 140S to the respective operator staging area 140A, where the operator 141 picks break-pack goods BPG from the supply container 265 for placement in the goods bot 262 or another container 265S, 264. In one embodiment, the operator staging area 140A may be adjacent to and / or formed by the support surface 140S. As described herein, the supply case 265 with goods remaining after break-packing is performed may be picked from the support surface 140S or staging area 140A by the container bot 110 and returned to the storage area or lift 150. The empty supply container 265 may be removed from the support surface 140S or staging area 140A by the operator 141 and stored in the break-pack operation station 140, and later retrieved by any suitable method. In one or more embodiments, the container bot 110 may transport the empty containers from the storage and retrieval system via the lift 150. In one or more embodiments, the breakpack operation station 140 includes an optional suitable waste removal system 223 for removing waste (or rubbish, e.g., shrink wrap, packaging, boxes, etc.) from the storage and retrieval system. In one or more embodiments, the waste removal system 223 includes one or more chutes, conveyors, lifts, or any other suitable conveying devices configured to move the waste to a designated location, but in other embodiments, the waste may be placed in containers and removed from the storage and retrieval system by the container bot 110 via the lift 150. As seen in Figures 2C and 13, the breakpack goods transfer deck 130DG merges with the breakpack operation station 140 and the container transfer deck 130DC at a location separate from each access of the container transfer deck 130DC to the breakpack operation station 140 (e.g., on a common support surface 140S) for the container bot 110 (e.g., at the breakpack goods interface location 263L).

[0040] In one embodiment, also referring to Figure 2D, one or more breakpack modules 266 include two or more (i.e., multiple levels) of goods transfer decks 130DG1 to 130DG3 stacked vertically, while in other embodiments, one or more breakpack modules may have a single level where the elevated level of at least one breakpack module is connected to a container transfer deck level. Here, the breakpack goods interface 263 may substantially resemble a rack as shown in Figure 1B and may include multi-level levels 130DGL1 to 130DGL3, each accessible from a common (level) container transfer deck 130DC. The container bot 110 can be any suitable independently operating autonomous transport vehicle that transports and transfers case units along the X and Y throughput axes throughout the storage and retrieval system 100. In one embodiment, the container 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 No. 10,822,168 issued on 3 November 2020, U.S. Patent No. 8,425,173 issued on 23 April 2013, U.S. Patent No. 9,561,905 issued on 7 February 2017, U.S. Patent No. 8,965,619 issued on 24 February 2015, and U.S. Patent No. 8, issued on 15 April 2014, which are included herein by reference in their entirety. This can be seen in U.S. Patent No. 696,010, U.S. Patent No. 9,187,244 issued on November 17, 2015, U.S. Patent No. 11,078,017 issued on August 3, 2021, U.S. Patent No. 9,499,338 issued on November 22, 2016, U.S. Patent No. 10,894,663 issued on January 19, 2021, and U.S. Patent No. 9,850,079 issued on December 26, 2017. The container bot 110 (described in more detail below) may be configured to place case units such as the above-mentioned retail goods into a picking stock at one or more levels of the storage structure 130, and then selectively retrieve the ordered case units.

[0041] In one embodiment, a pick face (which may include a supply container 265) is transported between the receiving section of the storage and retrieval system 100 (e.g., receiving station 160IN) and the loading filling section of the storage and retrieval system 100 (e.g., unloading station 160UT or unloading station 160EC) where a pick face to be deposited into the array is created, and where the pick face to be unloaded from the array is positioned to fill the load according to a predetermined loading filling order sequence or to fulfill one or more individual fulfillment orders according to a predetermined individual fulfillment order sequence. In another embodiment, a pick face (e.g., of a supply container 265) is transported between the storage space 130S and the loading filling section of the storage and retrieval system 100 (e.g., unloading station 160UT or unloading station 160EC) to fill the load according to a predetermined loading filling order sequence or to fulfill one or more individual fulfillment orders according to a predetermined individual fulfillment order sequence. In yet another embodiment, (one or more) breakpack goods containers 264 (in one embodiment, multiple breakpack goods containers may be placed on a pick face and transported as a pick face) are transported between the storage space 130S and the load filling section, and / or between the breakpack goods interface 263 of (one or more) breakpack modules 266 and the load filling section of the storage and retrieval system 100 (e.g., unloading station 160UT or unloading station 160EC) to fill loads according to a predetermined load filling order sequence, or to fulfill (one or more) individual fulfillment orders according to a predetermined individual fulfillment order sequence.

[0042] Other suitable features of the container bot 110, the lift module 150, and the storage and retrieval system 100 are controlled in any suitable manner, for example, via any suitable network 180, by, for example, one or more central system control computers (e.g., control servers) 120. In one embodiment, the network 180 is a wired network, a wireless network, or a combination of wireless and wired networks using any suitable type and / or number of communication protocols. In one embodiment, the control server 120 includes a set of programs (e.g., system management software) that run substantially simultaneously for substantially automated control of the automated storage and retrieval system 100. A set of programs running substantially simultaneously is configured to manage the storage and retrieval system 100, including, for illustrative purposes only, controlling, scheduling, and monitoring the activities of all active system components; managing inventory (e.g., which case units are brought in and retrieved, the order in which cases are retrieved, and where the case units are stored) and pick faces (e.g., one or more case units that are movable as units and are handled as units by the components of the storage and retrieval system); and interface with the warehouse management system 2500. In one embodiment, the control server 120 may be configured to control the features of the storage and retrieval system in the manner described herein. For simplicity and ease of explanation, the term “(one or more) case units” is used herein to generally refer to both individual case units and pick faces (a pick face is formed by multiple case units that are moved as units).

[0043] See also Figures 1B and 1C, 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, as will be described in more detail below. Rails 1200S may be attached, for example, to one or more of the vertical support members 1212 and horizontal support members 1200 in the picking aisle 130A, and container bots 110 may be configured to ride along the rails 1200S through the picking aisle 130A. At least one side of the picking aisle 130A of at least one storage level 130L may have one or more storage shelves (formed, for example, by rails 1210, 1200 and slats 1210S). In one embodiment, one or more shelves may be provided at different heights to form multiple shelf levels 130LS1 to 130LS3 between storage or deck levels 130L defined by the transport deck 130B (and rails 1200S forming the aisle deck). Therefore, there are multiple rack shelf levels 130LS1 to 130LS3 corresponding to each storage level 130L, extending along one or more picking passages 130A that communicate with the container transfer deck 130DC of each storage level 130L. As can be understood, the multiple rack shelf levels 130LS1 to 130LS3 give rise to each storage level 130L, and each storage level 130L has stacks of stored case units / supply containers 265 (or case layers) and / or stacks of stored breakpack merchandise containers 264 (or breakpack layers) accessible from a common deck 1200S of each storage level 130L (for example, stacks of stored cases are located between storage levels).

[0044] As can be understood, a container bot 110 traveling along the picking aisle 130A at the corresponding storage level 130L has access to each storage space 130S available at each shelf level 130LS1-130LS3 (for example, for picking and placing case units and / or break-pack merchandise containers), where each shelf level 130LS1-130LS3 is located between adjacent vertically stacked storage levels 130L on one or more sides PAS1, PAS2 (see, for example, Figure 2A) of the picking aisle 130A. As described above, each of the storage shelf levels 130LS1-130LS3 is accessible by the container bot 110 from the rail 1200 (for example, from the common picking aisle deck 1200S corresponding to the container transfer deck 130DC at each storage level 130L). As can be seen in Figures 1B and 1C, there are one or more intermediate shelf rails 1210B, 1210C spaced perpendicularly (for example, in the Z direction) to each other (and from rail 1200) to form a plurality of stacked storage spaces 130S, each accessible by container bots 110 from a common rail 1200S. As can be understood, the horizontal support members 1200 also form shelf rails on which case units are placed (in addition to shelf rails 1210).

[0045] Each stacked shelf level 130LS1 to 130LS3 (and / or each single shelf level described below) of the corresponding storage level 130L defines an open and non-deterministic two-dimensional storage surface (for example, having a case unit / break pack merchandise container CUSP as shown in Figure 1C) that facilitates the dynamic allocation of pick faces (e.g., supply containers 265) and / or break pack merchandise containers 264 longitudinally (e.g., along the length of the aisle or in accordance with the path of bot travel defined by the picking aisle) and transversely (e.g., across the aisle or path of bot travel, relative to the rack depth). The dynamic allocation of pick faces and the case units constituting the pick faces is provided, for example, in the manner described in U.S. Patent No. 8,594,835, issued November 26, 2013, the entire disclosure of which is incorporated herein by reference. Figure 1B illustrates that the supply container 265 is stored in the side PAS2 of the picking aisle 130A, and the breakpack merchandise container 264 is shown stored in the side PAS1 of the picking aisle 130A. In other embodiments, there may be combinations of supply containers 265 and breakpack merchandise containers 264 stored in common side PAS1, PAS2 (for example, one or both of side PAS1, PAS2) of the picking aisle 130A, and / or combinations of supply containers 265 and breakpack merchandise containers 264 stored on a common shelf surface.

[0046] In one embodiment, referring to Figures 1D and 3B, each of the storage levels 130L includes a single-level storage rack for storing a single-level case unit (for example, each storage level includes a single case unit support surface CUSP), and the container bot 110 is configured to transport the case units to and from the storage racks of each storage level 130L. For example, the container bot 110' illustrated in Figure 3B is substantially similar to the container bot 110 described herein, but the container bot 110' does not provide sufficient Z-movement of the transport arm 110PA for positioning the case units on multiple storage rack levels 130LS1 to 130LS3 as described above (for example, accessible from a common rail 1200S). Here, the transfer arm drive unit 250 (which may substantially resemble one or more of the drive units 250A, 250B) includes only sufficient Z movement to lift the case unit from the case unit support surface CUSP of a single-level storage rack, to transfer the case unit to and from the payload area 110PL, and to transfer the case unit between the fingers 273 of the transfer arm 110PA and the payload platform 110PB. A suitable example of the container bot 110' can be found, for example, in U.S. Patent No. 9,499,338 issued November 22, 2016, the entire disclosure of which is incorporated herein by reference.

[0047] Referring again to Figure 2A, each container transfer deck 130DC or storage level 130L includes one or more lift pick face interface / handoff stations TS (hereinafter referred to as interface stations TS), where (one or more) case units (e.g., individual case units, pick faces, supply containers, etc.), totes and / or break-pack goods containers 264 are transferred between the lift load handling device LHD and the container bot 110 on the container transfer deck 130DC. The interface stations TS are located on the side of the container transfer deck 130DC opposite to the picking aisle 130A and rack module RM, thereby interposing the container transfer deck 130DC between the picking aisle and each interface station TS. As described above, each container bot 110 at each picking level 130L has access (via each container transfer deck 130DC) to each storage position 130S, each picking aisle 130A, and each lift 150 at each storage level 130L, so that each container bot 110 also has access to each interface station TS at each level 130L. In one embodiment, the interface station is offset from the high-speed bot travel path HSTP along the container transfer deck 130DC such that the container bot 110's access to the interface station TS is nondeterministic with respect to the bot speed on the high-speed bot travel path HSTP. In this way, each container bot 110 can move (one or more) case units (e.g., individual case units, pick faces (constructed by the bot), supply containers, etc.), totes, and / or break-pack merchandise containers 264 from all interface stations TS to all storage spaces 130S corresponding to deck level 130L (and vice versa).

[0048] In one embodiment, the interface station TS is configured for the passive transfer (e.g., handoff) of case units (e.g., individual case units, pick faces, supply containers, etc.), totes, and / or break-pack goods containers 264 between the container bot 110 and the load handling device LHD of the lift 150, which are described in more detail below (e.g., the interface station TS does not have any moving parts for transporting the case units). For example, also referring to Figure 2B, the interface station TS and / or buffer station BS include one or more stacked levels TL1, TL2 of transport rack shelves RTS (each formed by rails 1210, 1200 and slats 1210S) substantially similar to the above-described storage shelves (each formed by rails 1210, 1200 and slats 1210S) so that the container bot 110 is handed off (e.g., picking and positioning) in a passive manner substantially similar to the method between the container bot 110 and the storage space 130S (as described herein) to which the case unit or tote is transported to / from the shelves (e.g., taking advantage of the lifting capacity of the container bot 110 over the stacked rack shelves RTS). In one embodiment, the buffer station BS on one or more of the stacked levels TL1, TL2 also functions as a handoff / interface station to the load handling device LHD of the lift 150. In one embodiment, if a bot such as a container bot 110' is configured for the transfer of case units (e.g., individual case units, pick faces, supply containers, etc.), totes, and / or break-pack merchandise containers 264 to a single level 130L of storage shelves, the interface station TS and / or buffer station BS also include a single level of transfer rack shelves (much like the storage rack shelves of storage level 130L described above with respect to Figure 1C, for example). As can be understood, the operation of the storage and retrieval system in which the container bot 110' works on a single level of storage and transfer shelves is substantially similar to the operation described herein.As can also be understood, the handoff (e.g., picking and positioning) of case units (e.g., individual case units, pick faces, supply containers, etc.), totes, and / or breakpack merchandise containers 264 from the loading handling device LHD (or lift) to stacked rack shelves RTS (and / or single-level rack shelves) is carried out in a passive manner substantially similar to the method by which the case units, totes, and / or breakpack merchandise containers 264 are transferred to / from the shelves between the container bot 110 (as described herein) and the storage space 130S. In other embodiments, the shelves may include a transfer arm for picking and positioning case units, totes, and / or breakpack merchandise containers 264 from one or more loading handling device LHDs of the container bot 110 and lift 150. A good example of an interface station using an active transfer arm is described, for example, in U.S. Patent No. 9,694,975, issued 4 July 2017, the entire disclosure of which is incorporated herein by reference.

[0049] In one embodiment, the position of the container bot 110 relative to the interface station TS occurs in substantially similar manner to the position of the bot relative to the storage space 130S. For example, in one embodiment, the position of the container bot 110 relative to the storage space 130S and the interface station TS occurs in substantially similar manner to the method described in U.S. Patent No. 9,008,884 issued April 14, 2015 and U.S. Patent No. 8,954,188 issued February 10, 2015, the entire disclosure of which is incorporated herein by reference. For example, referring to Figures 1 and 1C, the container bot 110 includes one or more sensors 110S that detect slats 1210S or positioning feature elements 130F (such as openings, reflective surfaces, or RFID tags) positioned on / within the rail 1200. The slats and / or positioning feature elements 130F are positioned, for example, to identify the position of the container bot 110 in the storage and retrieval system relative to the storage space and / or the interface station TS. In one embodiment, the container bot 110 includes a controller 110C that, for example, counts slats 1210S to determine at least partially the position of the container bot 110 within the storage and retrieval system 100. In another embodiment, the positioning feature unit 130F may be arranged to form an absolute or incremental encoder that provides a determination of the position of the container bot 110 within the storage and retrieval system 100 when detected by the container bot 110.

[0050] As can be understood, referring to Figure 2B, the transport rack shelf RTS at each interface / handoff station TS defines a multi-load station on a common transport rack shelf RS (for example, having one or more storage case unit holding positions for holding a corresponding number of case units or totes). As described above, each load at the multi-load station is either a single case unit / tote / breakpack container or a multi-case pick face (for example, having multiple case unit / tote / breakpack product containers that are moved as a single unit) that is picked and placed by either the container bot 110 or the load handling device LHD. Also as can be understood, the position of the bot described above allows the container bot 110 to position itself relative to the multi-load station for picking and placing case units / totes and pick faces from a given position in the holding positions of the multi-load station. The interface / handoff station TS defines multi-place buffers (for example, buffers with one or more case holding positions) where incoming and / or outgoing case units / totes / breakpack goods containers and pick faces are temporarily stored when they are transferred between the container bot 110 and the load handling device LHD of the lift 150.

[0051] In one embodiment, one or more peripheral buffer / handoff stations BS (which are substantially similar to interface stations TS and referred to herein as buffer stations BS) are also located on the side of the container transport deck 130DC opposite the picking aisle 130A and rack module RM, thereby interposing the container transport deck 130DC between the picking aisle and each buffer station BS. The peripheral buffer stations BS are scattered between interface stations TS or, otherwise, in one embodiment, lined with them 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 a continuation (but 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 also include one or more stacked levels TL1, TL2 of transport rack shelves RTS as described above with respect to 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 / break pack merchandise containers and / or pick faces are temporarily stored when they are transferred from one container bot 110 to another different container bot 110 on the same storage level 130L, as will be described in more detail 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 picking passage 130A and along the container transfer deck 130DC.

[0052] Still referring to Figures 2A and 2B, in one embodiment, at least the interface station TS is located on an extension extending from the container transport deck 130DC or on a pier 130BD, while in other embodiments, the length of the interface station TS may be located along and extended from the container transport deck. In one embodiment, the pier 130BD is similar to a picking passage on which container bots 110 travel along rails 1200S fixed to horizontal support members 1200 (in a manner substantially similar to the method described above). In other embodiments, the running surface of the pier 130BD may substantially resemble the running surface of the container transport deck 130DC. Each pier 130BD is located on the side of the container transport deck 130DC, such as on the opposite side from the picking passage 130A and rack module RM, thereby interposing the container transport deck 130DC between the picking passage and each pier 130BD. One or more piers 130BD extend 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 other embodiments, (one or more) peers 130BD extend from any suitable portion of container transport deck 130DC, including the ends 130BE1, 130BE2 of container transport deck 130DCD. As can be understood, a peripheral buffer station BSD (much similar to the peripheral buffer station BS described above) may also be positioned along at least a portion of peer 130BD.

[0053] Referring to Figure 3A, the container bot 110 transports case units between each lift module 150 and each storage space 130S at their respective storage levels 130L, as described above. The container bot 110 includes a frame 110F having a drive section 110DR and a payload section 110PL. The drive section 110DR includes one or more drive wheel motors, each connected to one or more drive wheels 202, to propel the container bot 110 along a passageway on the container deck 130DC and / or picking passageway 130A. In this embodiment, the container bot 110 includes two drive wheels 202 positioned on opposing sides of the container bot 110 at the end 110E1 of the container bot 110 (e.g., the first longitudinal end) to support the container bot 110 on a suitable drive surface, but in other embodiments, any suitable number of drive wheels may be provided on the container bot 110. In one embodiment, each drive wheel 202 is independently controlled so that the container bot 110 can be steered by the differential rotation of the drive wheels 202; however, in another embodiment, the rotations of the drive wheels 202 may be coupled to rotate at substantially the same speed. Any suitable wheel 201 is attached to the opposing frames on both sides of the container bot 110 at the ends 110E2 of the container bot 110 (e.g., the second longitudinal end) to support the container bot 110 on the drive surface. In one embodiment, the wheel 201 is a caster wheel that rotates freely to change the direction of travel of the container bot 110, allowing the container bot 110 to pivot by the differential rotation of the drive wheels 202. In another embodiment, the wheel 201 is a steerable wheel that changes direction to change the direction of travel of the container bot 110, for example under the control of a bot controller 110C (configured to provide control of the container bot 110 as described herein). In one embodiment, the container bot 110 includes, for example, one or more guide wheels 110GW positioned at one or more corners of the frame 110F.The guide wheel 110GW may interface with a storage structure 130, such as a guide rail (not shown) in a picking passage 130A, on the container transfer deck 130DC and / or at an interface or transfer station for interface with a lift module 150, for guiding the container bot 110 and / or positioning the container bot 110 at a predetermined distance from the location where one or more case units are placed and / or picked, as described in U.S. Patent No. 9,561,905 issued February 7, 2017, the entire disclosure of which is incorporated herein by reference.

[0054] As described above, the container bot 110 can enter the picking passage 130A having different facing directions for accessing the storage spaces 130S located on either side of the picking passage 130A. For example, the container bot 110 can enter the picking passage 130A with its end 110E2 leading in the direction of travel, or the bot can enter the picking passage 130A with its end 110E1 leading in the direction of travel.

[0055] The payload section 110PL of the container bot 110 includes a payload platform 110PB, a fence or datum member 110PF, a transport arm 110PA, and a pusher bar or member 110PR. In one embodiment, the payload platform 110PB includes one or more rollers 110RL mounted laterally to the frame 110F (for example, with respect to the longitudinal axis LX of the container bot 110) so that one or more case units and / or breakpack product containers carried into the payload section 110PL can be moved longitudinally along the longitudinal axis of the bot (for example, aligned with respect to the frame / payload section and / or datum reference of one or more case units) to position the case units and / or breakpack product containers in a predetermined position within the payload section 110PL and / or relative to other case units and / or breakpack product containers within the payload section 110PL (for example, longitudinal forward / backward positioning of the case units). In other embodiments, the container bot 110 includes one or more longitudinally movable pusher bars (not shown) for pressing the case units and / or break-pack product containers onto rollers 110RL to move (one or more) case units and / or (one or more) break-pack containers into a predetermined position within the payload section 110PL (for example, substantially similar to those described in U.S. Patent No. 11,078,017 issued on August 3, 2021, which is incorporated herein by reference in its entirety).

[0056] Still referring to Figure 3A, the case units and / or breakpack merchandise containers are placed on the payload platform 110PB and removed from the payload platform 110PB by the transfer arm 110PA. The transfer arm 110PA includes, for example, a lift mechanism or unit 200 substantially located within the payload section 110PL, as described in U.S. Provisional Patent No. 9,850,079, issued December 26, 2017, which is incorporated herein by reference in its entirety. The lift mechanism 200 provides both rough and precise positioning of pick faces (which may include either case units or breakpack merchandise containers, or both) carried by the container bot 110, which is lifted vertically to a position in the storage structure 130 for picking and / or positioning the pick faces and / or individual case units into the storage space 130S (for example, at each storage level 130L where the container bot 110 is located). For example, the lift mechanism 200 picks and places case units on multiple elevated storage shelf levels 130LS1-130LS3, TL1, and TL2, accessible from a common picking aisle or interface station deck 1200S (see, for example, Figures 1B, 2B, and 2D).

[0057] Still referring to Figure 3A, the picking head 270 of the container bot 110 transports the case unit between the container bot 110 and the picking / placement locations of the case unit and / or breakpack product container, such as the storage space 130S, peripheral buffer stations BS, BSD, interface station TS (see Figures 2A-2B), breakpack operation station 140 (see Figures 1 and 2C), product setting and container closing station 155, and / or breakpack product interface 263 (see Figures 1A and 2C), and in other embodiments, substantially directly between the container bot 110 and (one or more) lift modules 150. In one embodiment, the picking 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 ride along the 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 1C, the tines 273A-273E are configured to be inserted between the slats 1210S (and similar slats of the peripheral buffer stations BS, BSD, interface station TS, breakpack operation station 140, and / or breakpack merchandise interface 263) that form the case unit support surface CUSP of the storage rack.

[0058] Referring again to Figure 3A, it is 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 way, such as by a guide rod and slide configuration, and is actuated along the Y direction (for example, laterally, substantially parallel to the extension / retraction direction of the transfer arm 110PA). In one embodiment, at least one guide rod 360 is mounted in the payload 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 and slide along each guide rod 360. In one embodiment, at least the guide rod / slide configuration captures and holds the pusher bar 110PR within the payload section 110PL. 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 303T is a belt and pulley transmission. In another embodiment, the pusher bar 110PR may be actuated by a linear actuator that has substantially no rotating components. The pusher bar 110PR can result in the positioning of the case unit CY on the payload platform 110PB along the lateral axis of the container bot, and can result in the gripping of the case unit CU within the payload platform 110PB (for example, gripping between the pusher bar 110PB and the fence 110PF).

[0059] Referring here to Figures 1A, 1G, 2A, 2C, 2E, and 4, as described above, at least one product sorting and container closing station 155 may be connected to the structure of the automated storage and retrieval system 100 at any suitable location and at any suitable level 130L (one or more). For example, the product sorting and container closing station may be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC (such as in place of the storage rack module RM / picking aisle 130A or lifts 150A, 150B, or as an extension of one or more picking aisles 130A), or at one or more sides 130BD1, 130BD2 of the container transfer deck 130DC. Each of the goods sorting and container closing stations 155 is a plug-and-play module, which is integrated with (or otherwise connected to) the container transport deck 130DC so that the container transport deck 130DC is connected to at least one autonomous guidance vehicle interface 401, 402 of the goods sorting and container closing station 155 (also known as the container loading section 401, loading section 401 or loading interface station 401, and the unloading section or unloading interface station 402, respectively), thereby allowing the container bot 110 to transport breakpack containers 264 from at least one breakpack station 266 to at least one goods sorting and container closing station 155 via the container transport deck 130DC. In another embodiment, at least one autonomous guided vehicle interface 401, 402 interfaces with a container bot 110 traveling along a picking passage (see Figure 2A) extending from a container transport deck 130DC, and is connected to communicate with the picking passage so that the container bot 110 can transport breakpack containers 264 from at least one breakpack station 266 to at least one goods sorting and container closing station 155 via the picking passage 130A.If at least one autonomous guidance vehicle interface 401, 402 interfaces with a picking passage 130A, it should be noted that the picking passage 130A may include a non-deterministic turning area (similar to an open non-deterministic container transfer deck 130DC) where the container bot 110 can change direction and transfer the breakpack container 264 to at least one autonomous guidance vehicle interface 401, 402. If at least one autonomous guidance vehicle interface 401, 402 interfaces with a container transfer deck 130DC, the container transfer deck may include a transfer lane where the container bot 110 can "parallel park" adjacent to a given autonomous guidance vehicle interface 401, 402 for the transfer of the breakpack container 264 between the container bot 110 and the autonomous guidance vehicle interface 401, 402.

[0060] One or more product setting and container closing stations 155 form a product order fulfillment system (or part thereof) for mixed product units held in containers 264 for transport. As described herein, each product setting and closing station 155 includes a synchronous transport system 410S that forms a container transport route CTP for transporting containers 264. The synchronous transport system 410S has a container loading section (also called an autonomous guided vehicle interface) 401 arranged to communicate with an asynchronous container transport device (such as a container bot 110) for loading containers 264 into the synchronous transport system 410S. At least one container setting device (also called a product setting device herein) 420 is configured to engage with a container 264 as it is transported along the container transport route CTP to set the mixed product units held in the container 264, thereby causing the container 264 to swing. At least one container lid closing device (also referred to herein as a container closing bay) 430 is configured to engage with the lid 264L (see Figure 8B) of a container 264 being transported along a container transport path CTP to close the lid 264L. The at least one container lid closing device 430 and the at least one container settling device 420 are connected in communication with each other by the container transport path CTP, and the synchronous transport device 410S includes an intervening switch selector 499 that controls the container transport path CTP to orient the container 264 toward at least one container settling device 420, at least one container lid closing device 430, and at least one of both the at least one container settling device 420 and the at least one container lid closing device 430.

[0061] The intervening switch selector 499 includes at least one container inspection station 498 (see container inspection station 498A) equipped with a sensor 498S configured to detect the height of at least one mixed product unit BPG within the container 264. The height of the mixed product unit BPG (see, for example, height 264H in Figure 8B) can be used to measure the distance from the bottom of the container 264 to the top of the container as defined by the top 264T of the container 264 (see Figure 5D), the lid 264L of the container 264, or the lid portions 264L1, 264L2 of the container 264 (e.g., after the lid 264L is closed), or the distance from the bottom of the container 264 to the top of the product unit extending above the top 264T of the container 264 (e.g., before the lid 264L is closed). The intervening switch selector 499 is positioned to controllably select a container transport path CTP so that, based on height, the container 264 is directed towards at least one of the container leveling devices 420 and bypasses the container leveling device 320. For example, if the mixed product unit BPG does not extend above the top 264T of the container 264, the intervening switch selector 499 selects a container transport path CTP to bypass the container leveling device 320.

[0062] The intervening switch selector 499 includes another container inspection station 498B downstream from at least one container inspection station 498A along the container transport path CTP. The other container inspection station 498B has another sensor 498S configured to detect the height of the mixed product unit BPG in the container 264 as it passes through the other container inspection station 498B. The intervening switch selector 499 is positioned to controllly select the container transport path CTP so as to orient the container 264 towards at least one of the at least one container lid closing device 430 and to bypass the container lid closing device 430, based on the height. For example, if the mixed product unit BPG extends above the top 264T of the container 264 (e.g., after settling), the intervening switch selector 499 selects the container transport path CTP to bypass the container lid closing device 320. The other container inspection station 498B is positioned on the transport path CTP between at least one container settling device 420 and at least one container lid closing device 430.

[0063] The intervening switch selector 499 may also include a further container inspection station 498C having a further sensor 498S configured to detect the height of the mixed product unit BPG inside the container 264 as it passes through the further container inspection station 498C. The intervening switch selector 499 is positioned to controllly select a container transport path CTP so as to orient the container 264 towards at least one of the unloading interface stations 402 and to bypass the unloading interface station 402, based on the height. For example, if the mixed product unit BPG extends above the top 264T of the container 264 (for example, if the lid 264L is not closed after the lid 264L has been closed), the intervening switch selector 499 selects a container transport path CTP so as to bypass the unloading interface station 402 and divert the container 264 to an intervening station 466 for correction. Another container inspection station 498C is positioned on the transport path CTP between at least one container lid closing device 430 and the unloading interface station 402.

[0064] Each of the goods setting and container closing stations 155 includes at least one autonomous guided vehicle interface 401, 402, a transport device 410, a goods setting device (also referred to herein as a container setting device) 420, and a container closing bay 430. The transport device 410 is a synchronous transport device and is configured to transport break-pack goods containers 264 within each goods setting and container closing station 155. The transport device 410 includes a container loading section formed by the autonomous guided vehicle interface 401, which is configured to communicate with an asynchronous container transport device to load containers 264 with their lids 264L open from the asynchronous container transport device to the synchronous transport device. The transport device 410 also includes a container unloading section formed by the autonomous guided vehicle interface 402, which is configured to communicate with an asynchronous container transport device to unload containers 264 with their lids 264L closed from the synchronous transport device to the asynchronous transport device. The transport device 410 is any suitable transport device configured to transport breakpack product containers 264 between the autonomous guided vehicle interfaces 401, 402 and one or more of the product leveling devices 420 and container closing bays 430. The transport device 410 may be a roller conveyor, belt conveyor, ball conveyor, and / or any other suitable conveyor type or combination of conveyor types that result in the transport of breakpack product containers 264 within each product leveling and container closing station 155.

[0065] Although the autonomous guided vehicle interfaces 401, 402 are described as forming the respective loading and unloading sections of the transport device 410, in other embodiments, a single bidirectional autonomous guided vehicle interface 401, 402 may be provided that forms the loading / unloading section of the setting and container closing station 155. The autonomous guided vehicle interfaces 401, 402 may be passive interfaces having a structure substantially similar to those illustrated in Figures 1C and 2B with respect to the storage shelves and buffers and transport stations BS, TS of the rack module RM, thereby allowing the container bot 110 to transport breakpack containers 264 between the autonomous guided vehicle interfaces 401, 402 and the transport arm 110PA in a manner substantially similar to that described herein. The autonomous guided vehicle interfaces 401, 402 include any suitable container drive device configured to move the breakpack container from each of the autonomous guided vehicle interfaces 401, 402 to the transport device 410 (or from the transport device 410 to each of the autonomous guided vehicle interfaces 401, 402) (e.g., a pusher, spaced-out drive rollers (spaced out in a manner similar to slats 1210S in which the fingers of the transport arm 110PA are inserted into the space between the rollers)).

[0066] See also Figures 5A-5E, the product settling device 420 is configured to periodically oscillate, or otherwise vibrate, the breakpack product container 264 along a multidimensional reciprocating (periodic) motion path so that the products in the breakpack product container 264 are settled within the breakpack product container 264. Here, the product BPG is moved within the breakpack product container 264 under the propulsion of the product settling device 420. The oscillating motion of the product BPD minimizes the space between the product BPGs so that the product BPG is positioned substantially entirely below the plane PL defined by the upper part 264T (see Figure 5D) of the breakpack product container 264, thereby allowing the lid 264L (see Figure 4) of the breakpack product container 264 to close substantially without disturbing the products. The product settling device 420 includes a frame 500, a container platform 520, and a drive unit 530. As can be understood, the product settling device 420 includes any suitable controller 598 configured to bring the operation of the product settling device 420 in the manner described herein. The controller 598 can be connected to the control server 120 in any suitable manner to enable communication, or it can form part of the control server 120.

[0067] The container platform 520 has opposing sides or ends 521, 522. Each of the opposing sides 521, 522 is connected to the frame 500 at their respective pivot joints 523, 524. One end of the container platform 520 is connected to the frame 500 at pivot joint 523 by a link (also referred herein as a pivot link) 525. The opposite end of the pivot link 525 is pivotably connected to the frame at pivot joint 505. The other pivot joint 524 forms a fulcrum 524F on which the side 522 pivots. The fulcrum 524F is offset from the pivot joint 523 of the link 525 to the container platform 520 along the length of the container platform 520.

[0068] Referring to Figure 5E, the pivot point 524F formed by the pivot joint 524 is fixed to the frame 500 in a stationary position. Here, the container platform 520 slides on the pivot point 524F and pivots about the pivot point 524F. For example, the container platform 520 includes a rail 599R that slides and engages with the pivot joint 524 so that the container platform moves in direction MA relative to the pivot point 524F. The pivot joint 524 also causes rotation or pivoting of the rail 599R (and the container platform) about the pivot axis of the pivot point 524F so that the side 522 of the container platform 520 moves in direction MC. Here, the container platform 520 is suspended from the frame 500 by the pivot link 525 and the fulcrum 524F such that the pivot link 525 and the fulcrum 524F restrict the motion of the container platform 520 to movement along a multidimensional reciprocating motion path (see directions MA, MB, MC in Figure 5E) as described in more detail herein.

[0069] Referring to Figure 5C, the pivot point 524F formed by the pivot joint 524 is a movable or floating pivot point to which one end of another pivot link 526 is connected to the pivot platform 520 at the pivot joint 524. The other end of the other pivot link 526 is pivotably connected to the frame 500 at the pivot joint 506. Here, the container platform 520 is suspended from the frame 500 by pivot links 525, 526 such that the pivot links 525, 526 restrict the motion of the container platform 520 to movement along a multidimensional reciprocating motion path (see directions MA, MB, MC in Figure 5C) as described in more detail herein.

[0070] Still referring to Figures 5A-5E, the container platform 520 includes a container support surface 529 configured to support breakpack goods containers 264 held on the container platform 520. The container support surface 529 includes at least one platform roller 528 configured to perform one or more of the following: guiding breakpack goods containers into the container platform 520 and driving breakpack goods containers out of the container platform 520. Input / output rollers 527 may also be connected to the frame 500 and positioned to load and unload breakpack goods containers 264 into and out of the container platform 520. In some embodiments, the input / output rollers are driven rollers, while in other embodiments, the input / output rollers may be passive rollers. In some embodiments, at least one platform roller 528 and one or more of the input / output rollers 527 may be driven by any suitable roller drive 528D and positioned to drive containers into and out of the container platform 520. In other embodiments, the container platform 520 includes a pusher 575 (see Figure 5C) that extends linearly over at least a portion of the support surface 529 and pushes containers from the container platform 520 onto (driven or passive) rollers 257, 528 and / or transport devices 410.

[0071] The product setting device 420 also includes a container grip 550 movably connected to the frame 500 and configured to grip the breakpack product container 264 so that the breakpack product container 264 and the container platform 520 move as a unit. For example, the container grip 550 is attached to the container platform 520 so that it moves as a unit with the container platform 520. The container grip includes opposing grip plates 551A, 551B, each connected to the container platform by their respective actuators 552A, 552B. The actuators 552A, 552B are any suitable actuators (e.g., linear actuators, screw drives, etc.) configured to bring the opposing grip plates 551A, 551B closer to and further apart from each other, resulting in the gripping and releasing of the breakpack product container 264 located on the container platform 520, respectively (see Figures 5B and 5D illustrating the gripping of the breakpack product container 264). Each grip plate 551A, 551B includes a container gripping section 551AG, 551BG and a product storage section 551AC, 551BC. The container gripping sections 551AG, 551BG are configured to engage with opposing sides of the breakpack product container 264 and securely hold the breakpack product container 264 so that the breakpack product container 264 and the container platform 520 move as a unit. The product storage sections 551AC, 551BC are configured to contain goods within the breakpack product container 264 when the breakpack product container 264 is moved by the container platform 520 (for example, to provide product arrangement).

[0072] It should also be noted that the frame 500 may also include a fixed (e.g., stationary relative to the frame 500) goods storage wall 501 (not shown in Figure 5E for clarity) and a pivotable goods storage wall 502 (not shown in Figure 5E for clarity). The fixed goods storage wall 501 is positioned on the side opposite to the frame 500 for the entry / exit of containers brought about by at least one drive platform roller 528. The fixed goods storage wall 501 is positioned on the frame to restrict goods from exiting the breakpack goods container 264 (e.g., to bring the goods to a state of order) as the breakpack goods container 264 is moved by the container platform 520. The pivotable goods storage wall 502 is pivotably connected to the frame 500 and is positioned to block the entry / exit of containers to / from the container platform 520. The pivotable goods storage wall 502 is pivotable between an extended configuration and a retracted configuration (the retracted configuration is shown in Figures 5A and 5D). The deployed configuration of the pivotable goods storage wall 502 blocks the entry / exit of containers to / from the container platform and stores goods within the breakpack goods container 264 as it is moved by the container platform 520 (for example, goods are settled). The retracted configuration of the pivotable goods storage wall 502 (as illustrated in Figures 5A and 5D) provides unobstructed entry / exit of containers to / from the container platform 520.

[0073] The drive unit 530 is connected to the container platform 520 and configured to drive the container platform 520 in multidimensional reciprocating motion. As described above, each pivot link 525 and fulcrum 524F (regardless of whether the fulcrum is stationary and constrained by its connection to the frame 500, as illustrated in Figure 5E, or floating and constrained by the pivot link 526, as illustrated in Figures 5B-5D) constrains the reciprocating motion of each pivot joint 523, 524, and the container platform 520 to movement along a multidimensional reciprocating motion path (see Figures 5C and 5E as described herein). The drive unit includes a drive motor 530M, a cam 530C, and a crank link 530L. The drive motor 530M is connected to the frame in any suitable manner (e.g., using a fixture). The cam 530C is connected to the output of the drive motor 530M so that the drive motor 530M drives the rotation of the cam 530C about the drive rotation axis 530X. One end of the crank link 530L is eccentrically connected to the cam 530C around the pivot joint 530CJ, which follows a circular path CP around the drive rotation shaft 530X. The other end of the crank link 530L is pivotably connected to the container platform 520 at the pivot shaft 523.

[0074] As best seen in Figures 5C and 5E, as the cam rotates and the pivot joint 530CJ moves along the circular path CP, the crank link 530L causes a swing motion of the side 521 of the container platform in the MB direction, where the swing motion is constrained by the pivot link 525. As the side 521 moves in a swing motion in direction MB, the other side 522 of the container platform moves in a reciprocating swing motion in direction MC, constrained by the fixed position of the pivot link 526 (in Figure 5C) or the fulcrum 524F (in Figure 5E). Here, when side 521 moves in direction MB1 (for example, swings upward), the other side 522 moves in the reciprocating direction MC2 (for example, swings downward), while the entire container platform 520 moves in the linear direction MA1. Conversely, when side 521 moves in direction MB2 (for example, swings downward), the other side 522 moves in the reciprocating direction MC1 (for example, swings upward), while the entire container platform 520 moves in the linear direction MA2. This reciprocating swing motion of the container platform 520 in directions MB and MC, and the simultaneous linear motion of the container platform 520 in direction MA, form a multidimensional reciprocating motion path for the container platform 520. Here, the multidimensional reciprocating motion path of the container platform 520 is a periodic motion configured to shake or otherwise move the goods within the breakpack goods container 264 such that the goods are settled within the breakpack goods container 264 and below the upper part 264T of the breakpack goods container (for example, the goods do not extend above the plane PL formed by the upper part 264T).

[0075] The transport device 410 may include a product detection station 444 upstream of the product setting device 420, configured to determine whether the breakpack product BPG in each breakpack product container 264 extends above the plane PL formed by the upper part 264T of the breakpack product container 264. The product detection station 444 includes any suitable sensor 444S, which is positioned such that the breakpack product container 264 moving along the transport device 410 is within the field of view of the sensor 444S (in the case of an imaging sensor) or within the electromagnetic beam (in the case of a break-the-beam or reflective beam sensor). If the sensor 444S detects a breakpack product above the plane PL, the product detection station 444 uses the transport device 410 to transport the breakpack product container 264 to the product setting device 420; otherwise, the breakpack container 264 may bypass the product setting device 420 and be transported to the container closing bay 430.

[0076] Referring to Figures 4, 6A, 6B, 7A, 7B, 8A, and 8B, the container closing bay 430 is connected to the goods sorting device 420 by the transport device 410 so as to be able to communicate with it. The container closing bay 430 includes an opposing container lid manipulator having opposing helical guides 620A, 620B configured to engage with the respective lid portions 264L1, 264L2 of the break pack goods container 264 and to guide the closing movement of the respective lid portions 264L1, 264L2 from an open configuration to a closed configuration, as described herein.

[0077] The container closing bay 430 includes a frame 600, a bidirectional conveyor 610, and at least one opposing container lid manipulator (e.g., at least one receiving-side opposing container lid manipulator 620). The frame 600 includes an end plate 600P as further described herein. The bidirectional conveyor 610 is connected to the frame 600 in any suitable way (e.g., using any suitable fasteners). The bidirectional conveyor 610 is a roller conveyor, a belt conveyor, a ball conveyor, or any other suitable conveyor driven bidirectionally by a conveyor drive 610D to transport break-pack goods containers 264 and engage with and disengage from at least one opposing container lid manipulator 620, 630. The bidirectional conveyor 610 includes a goods container transport surface 610S and a drive section 610D configured to alternately drive the goods container transport surface 610S in a first direction or inbound direction 888 into the container closing bay 430 and in a second direction or outbound direction 889 out of the container closing bay 430, where the second direction 889 is opposite to the first direction 888. For example, as described in more detail herein, the bidirectional conveyor 610 receives an open breakpack goods container 264 from the transport device 410. The bidirectional conveyor 610 transports the open breakpack goods container 264 by engaging it with at least one opposing container lid manipulator 620, 630 so that the lid of the breakpack goods container is closed. The bidirectional conveyor 610 transports the now closed breakpack goods container 264 back to the transport device 410 for goods sorting and unloading from the container closing station 155. The container closure bay 430 includes any suitable controller 698 configured to bring the operation of the bidirectional conveyor 610 (and, where applicable, the working portion of the container closure bay 430) in the manner described herein.

[0078] At least one opposing container lid manipulator (e.g., inbound opposing container lid manipulator 620) has opposing helical guides or cams 620A, 620B, 630A, 630B configured to engage with each lid portion 264L1, 264L2 of the breakpack goods container 264 and guide the closing movement of each lid portion 264L1, 264L2 from an open configuration to a closed configuration. At least one opposing lid container manipulator 620, 630 includes inbound opposing helical guides 620A, 620B arranged to guide each lid portion 264L1, 264L2 of the breakpack goods container 264 to a semi-closed orientation when the breakpack goods container 264 is moving in a first direction or inbound direction 888 (see Figure 8A). Here, the opposing spiral guides 620A and 620B on the receiving side are configured to provide the lifting motion for closing their respective lid portions 264L1 and 264L2 (see Figure 8A).

[0079] One of the opposing helical guides, 620A, is the leading helix and is referred to herein for explanatory purposes as the leading helical guide 620A. The other opposing helical guide, 620B, is the trailing helix and is referred herein for explanatory purposes as the trailing helical guide 620B. As can be seen in Figures 6A-7A, the leading helical guide 620A has a different cam profile from the trailing helical guide 620B such that the cover portion 264L1 that engages with the leading helical guide 620A reaches and passes through the vertical orientation before the cover portion 264L2 that engages with the trailing helical guide 620B reaches and passes through the vertical orientation. The different cam profiles of the leading helical guide 620A and the trailing helical guide 620B may be called offset cam profiles, which result in offset timed camming clamshell closure of the lid portions 264L1 and 264L2, so that the upper locking portion 264F and the lower locking portion 264M of the lid portions 264L1 and 264L2 engage with each other and interlock.

[0080] At least one opposing container lid manipulator may include an outbound opposing container lid manipulator 630. The outbound opposing container lid manipulator 630 includes outbound opposing helical guides 630A, 630B arranged to guide each lid portion 264L1, 264L2 from a semi-closed orientation / configuration (similar to that illustrated in Figure 8B) to a closed orientation / configuration as the break-pack goods container 264 moves in a second direction 889. One of the outbound opposing helical guides 630A is a leading helix and is referred to herein for explanatory purposes as the outbound leading helical guide 630A. The other outbound opposing helical guide 630B is a trailing helix and is referred herein for explanatory purposes as the outbound trailing helical guide 630B. As can be seen in Figures 6A to 7A, the leading spiral guide 630A on the outbound side has a different cam profile from the trailing spiral guide 630B on the outbound side, such that when the break pack product container 264 is moving in the second direction 889, the upper locking portion 264F and lower locking portion 264M of the lid portions 264L1 and 264L2 are guided to a closed orientation throughout the entire offset timing cam clamshell closure of the lid portions 264L1 and 264L2 by the opposing spiral guides 630A and 630B on the outbound side, so that the lid portion 264L1 that engages with the leading spiral guide 630A on the outbound side is lower than the lid portion 264L2 that engages with the trailing spiral guide 630B on the outbound side.

[0081] In another embodiment, also referring to Figure 9, the outbound-facing container lid manipulator 630 includes a double outbound-facing spiral guide 900 positioned along a second direction 889 opposite to a first direction 888, so that, as the breakpack goods container 264 moves in the second direction 889, one of the outbound-facing spiral guides 910 (also called the first-stage double helix) engages with the leading portion of each lid portion 264L1, 264L2 in a semi-closed orientation, and the other outbound-facing spiral guide 920 (also called the second-stage double helix) engages with the trailing portion of each lid portion 264L1, 264L2 in a semi-closed orientation, thereby guiding each lid portion 264L1, 264L2 from a semi-closed orientation to a closed orientation (see Figure 9). Here, the double exit-side opposing helical guide 900 is configured for the stepped offset timing cam clamshell closing of the lid portions 264L1 and 264L2, such that the upper locking portion 264F and the lower locking portion 264M of the lid portions 264L1 and 264L2 engage with each other and interlock.

[0082] The double exit-side opposing helical guide 900 includes a first-stage double helix 910 configured to guide the closure of lid portions 264L1, 264L2 from a vertical orientation to an intermediate orientation. The double exit-side opposing helical guide 900 also includes a second-stage double helix 920 (for example, aligned with the first-stage double helix 910 along the exit direction 889) configured to guide the closure of lid portions 264L1, 264L2 from an intermediate orientation to a closed orientation. The intermediate orientation may be a position of each lid portion 264L1, 264L2 that is approximately midway between the vertical orientation and the closed orientation, but in other embodiments, the intermediate orientation may be a position greater than or less than approximately midway between the vertical orientation and the closed orientation. The first-stage double helix 910 includes helical guides 910A, 910B which are substantially similar to those described herein with respect to helical guides 630A, 630B. The second stage double helix 920 also includes helical guides 920A, 920B which are substantially similar to those described herein with respect to the helical guides 630A, 630B. Here, the second stage double helix 920 is offset from the first stage double helix 910 along the direction of movement 889 of the outgoing container, and the guided movement of the lid portion 264L1 transitions from being guided by the leading helical guide 910A to being guided by the leading helical guide 920A while the lid portion 264L1 is substantially in an intermediate orientation. Similarly, the lid portion 264L2 transitions from being guided by the trailing helical guide 910B to being guided by the trailing helical guide 920B while the lid portion 264L1 is substantially in an intermediate orientation. Here, the lid portions 264L1 and 264L2 are guided to close throughout substantially the entire offset timing cam clamshell closing of the lid portions 264L1 and 264L2 such that the upper locking portion 264F and the lower locking portion 264M of the lid portions 264L1 and 264L2 engage with each other and interlock.

[0083] The container closing bay 430 may also include lid guides 650A, 650B. The lid guides 650A, 650B are positioned on the frame 600 relative to the bidirectional conveyor 610 and the break-pack product containers 264 moving thereon, so as to pivot their respective lid portions 264L1, 264L2 away from the bin portion 264B. By pivoting the lid portions 264L1, 264L2 away from the bin portion 264B, the lid portions 264L1, 264L2 are positioned to engage with opposing helical guides 620A, 620B on their respective receiving sides. In other embodiments, the lid guides 650A, 650B may be integrated with the opposing helical guides 620A, 620B on the receiving side.

[0084] The container closing bay 430 is described as bidirectional to close the lid portions 264L1, 264L2 as the breakpack goods container 264 moves in a combination of a first direction 888 and a second direction 889, but in other embodiments (see Figures 10A and 10B), the container closing bay 430 may have a through-type (e.g., unidirectional) configuration. Here, the end plate is removed and the conveyor 610 extends beyond the downstream end DSE of the opposing helical guides 620A, 620B. The operation of the container closing bay 430 is similar to that described above, but in this embodiment, the breakpack goods container moves only in direction 888 through the container closing bay 430 so as to engage sequentially with the opposing helical guides 620A, 620B and one of the helical guides 630A, 630B (Figure 10A) and the double outbound opposing helical guide 900 (Figure 10B).

[0085] The transport device 410 may include an open lid detection station 445 downstream of the container closing bay 430, configured to detect the closing of the lid portions 264L1, 264L2 of each breakpack goods container 264. For example, the open lid detection station 445 includes any suitable sensor 445S positioned so that the breakpack goods container 264 moving along the transport device 410 is within the field of view of the sensor 445S (in the case of an imaging sensor) or within the electromagnetic beam (in the case of a beam-blocking or reflective beam sensor). If the sensor 445S detects (one or more) open lid portions 264L1, 264L2 (for example, lid portions 264L1, 264L2 extending beyond a predetermined height from the support surface of the transport device, where the predetermined height corresponds to the height of a closed breakpack product container), the open lid detection station 445 will use the transport device 410 to transport the breakpack product container 264 to the intervening station 446; otherwise, the breakpack container 264 may be transported to the discharge interface station 402, bypassing the intervening station 446. An operator (human or robot) at the intervening station 446 may correct the open lid and transport the breakpack product container 264 to the discharge interface station 402 via the transport device 410.

[0086] Referring to Figures 4, 8B, and 11A-11F, the container closing bay 430 includes an inbound-side opposing lid manipulator 1320, a lid support 1330, and an outbound-side lid manipulator 1350. The inbound-side opposing lid manipulator 1320 of the container closing bay 430 includes nonlinear guides 1320A and 1320B and is connected to the frame 600 in any suitable manner. In one or more embodiments, the nonlinear guides or cams 1320A, 1320B of the inbound-facing lid manipulator 1320 may be substantially similar to those of the inbound-facing container lid manipulator 620 described above, but in other embodiments, the nonlinear guides 1320A, 1320B may have (one or more) nonlinear or arched lid guide or cam surfaces / shapes configured to operate the lid portions 264L1, 264L2 as described herein, rather than being helical (for example, a portion of the guide surface may be linear but together form a nonlinear or substantially arched guide surface). Here, the nonlinear guides 1320A, 1320B may be substantially similar to having a non-offset cam profile (for example, the lid portions 264L1, 264L2 of container 264 may be engaged substantially simultaneously by the nonlinear guides 1320A, 1320B instead of in the shifted / offset method described above with respect to the inbound-facing container lid manipulator 620).

[0087] The frame 600 includes a linear guide 600G extending substantially perpendicular to the product container transport surface 610S. The lid support 1330 includes a carriage 1331 attached to the linear guide 600G in any suitable way (e.g., any suitable linear bearing) to reciprocate along the linear guide 600G in the Z direction. The lid support 1330 includes lid support tines 1330A, 1330B extending from the carriage 1331 over the product container transport surface 610S of the bidirectional conveyor 610. As described herein, the lid support tines 1330A, 1330B are spaced laterally apart from each other and positioned above the product container transport surface 610S to receive their respective lid portions 264L1, 264L2 from the nonlinear guides 1320A, 1320B and support the lid portions 264L1, 264L2 in a semi-closed orientation (see Figure 11C). The container closure bay 430 includes a lid support actuator 1371 mounted on the frame 600. The lid support actuator 1371 is coupled to a carriage 1331 (and the lid support tines 1330A, 1330B carried by it) and drives it in the Z direction along the linear guide 600G. The lid support actuator 1371 is any suitable actuator, including, but not limited to, one or more hydraulic pistons and / or pneumatic pistons, belts and pulleys, chains and sprockets, screw drives, magnetic drives, etc.

[0088] The outbound lid manipulator 1350 includes a carriage 1351 attached to the linear guide 600G in any suitable way (e.g., any suitable linear bearing) so as to reciprocate along the linear guide 600G in the Z direction. The outbound lid manipulator 1350 includes lid closing tines 1350A, 1350B extending from the carriage 1351 onto the goods container carrying surface 610S of the bidirectional conveyor 610. In some embodiments, the lid closing tines 1350A, 1350B include friction-reducing elements such as rollers 1350AR, 1350BR that engage with the lid portions 264L1, 264L2. As described herein, the lid closing tines 1350A, 1350B are spaced laterally apart from each other and positioned above the goods container carrying surface 610S, applying closing loads or forces to the lid portions 264L1, 264L2 supported on the lid support tines 1330A, 1330B (see Figure 11D). The container closing bay 430 includes a manipulator actuator 1372 mounted on the frame 600. The manipulator actuator 1372 is coupled to the carriage 1351 (and the lid closing tines 1350A, 1350B carried by it) and drives it in the Z direction along the linear guide 600G. The manipulator actuator 1371 is any suitable actuator, including, but not limited to, one or more hydraulic pistons and / or pneumatic pistons, belts and pulleys, chains and sprockets, screw drives, magnetic drives, etc.

[0089] Still referring to Figures 4, 8B, and 11A-11F, in the manner described herein, the bidirectional conveyor 610 receives an open breakpack goods container 264 from the transport device 410. The bidirectional conveyor 610 transports the open breakpack goods container 264 in direction 888 so that each of the lid portions 264L1, 264L2 of the breakpack goods container 264 is moved from an open configuration (see Figures 11A and 11B) to a semi-closed orientation, resting on the respective lid support tines 1330A, 1330B, and engaging with the opposing container lid manipulator 1320 (see Figure 11C). The exit-side lid manipulator 1350 is moved in the Z direction toward the lid portions 264L1 and 264L2 supported on the lid support tines 1330A and 1330B so that the lid closing tines 1350A and 1350B substantially contact the respective lid portions 264L1 and 264L2 (see Figure 11D).

[0090] With the lid closing tines 1350A and 1350B substantially in contact with the lid portions 264L1 and 264L2, both the outbound lid manipulator 1350 and the lid support 1330 are moved in the Z direction toward the product container transport surface 610S (at approximately the same rate / speed) so that the lid support tines 1330A and 1330B substantially contact the upper edge of the container 264 (see Figure 11E). As the outbound lid manipulator 1350 and the lid support 1330 move toward the product container transport surface 610S, the lid portions 264L1 and 264L2 are pivoted toward each other so that their respective upper locking portions 264F and lower locking portions 264M engage with each other. The exit-side lid manipulator 1350 may continue to move in the Z direction so that the upper locking portion 264F and the lower locking portion 264M of the lid portions 264L1 and 264L2 interlock with each other, or it may apply pressure / force in the Z direction to the lid portions (see Figure 11E).

[0091] With the lid closing tines 1350A and 1350B applying pressure / force to the lid portions 264L1 and 264L2, the bidirectional conveyor 610 is operated to drive the product container transport surface 610S in the outbound direction 889. The product container transport surface 610S transports the container 264 in direction 889, moving the container 264 away from the outbound-side lid manipulator 1350 and the lid support portion 1330. As illustrated in Figures 11E and 11F, the lid closing tines 1350A and 1350B of the outbound lid manipulator 1350 have a length LL1 that is longer than the length LL2 of the lid support tines 1330A and 1330B of the lid support 1330, such that when the container 264 is moved away from the outbound lid manipulator 1350 and the lid support 1330, contact between the lid closing tines 1350A and 1350B and the lid portions 264L1 and 264L2 follows contact between the lid support tines 1330A and 1330B and the lid portions 264L1 and 264L2 (i.e., with the container 264 moved in the outbound direction 889, the lid support tines 1330A and 1330B disengage from the lid portions 264L1 and 264L2 before the lid closing tines 1350A and 1350B). The interlock between the upper locking portion 264F and the lower locking portion 264M of the respective upper locking portions 264F and lower locking portions 264M of the respective upper locking portions 264L1 and 264L2 is maintained when the container 264 is moved in the outbound direction 889 for removal from the container closing bay 430 by the subsequent disengagement following the lid closing tines 1350A and 1350B from the lid portions 264L1 and 264L2.

[0092] The bidirectional conveyor 610 transports the currently closed break-pack product containers 264 back to the transport device 410 for product sorting and unloading from the container closing station 155. As described above, the container closing bay 430 includes any suitable controller 698 configured to bring the bidirectional conveyor 610, the outbound lid manipulator 1530, and the lid support 1330 into operation in the manner described herein.

[0093] Referring to Figures 1A, 1G, 4-11D, and 12, a method for container transport of a mixed product unit BPG in a product order fulfillment system 100 is described according to an aspect of the disclosed embodiment, where the mixed product unit BPG is held in a container 264 for transport. The method includes transporting the container 264 using a synchronous transport system that forms a container transport path CTP for transporting the container 264 (see Figures 1G-12, block 12100), and loading the container 264 into the synchronous transport system by a container loading section 401 of the synchronous transport system which communicates with an asynchronous container transport device (see Figure 1G). At least one container settling device 420 engages with the container 264 transported along the container transport path CTP (as described herein) to rock the container 264 (Figure 12, block 12110) and settle the mixed product unit BPG within the container 264. At least one container lid closing device engages with the lid 264L of a container 264 being transported along a container transport path CTP to close the lid 264L (as described herein - Figure 12, block 12120), where at least one container lid closing device 430 and at least one container settling device 420 are connected in communication by the container transport path CTP. The container transport path CTP is controllably selected by an intervening switch selector 499 of the synchronous transport device to orient the container 264 toward at least one container settling device 420, at least one container lid closing device 430, and at least one of both the at least one container settling device 420 and the at least one container lid closing device 430 (Figure 12, block 12130).

[0094] Referring to Figures 1A, 1G, 4-11D, and 13, a method for storing and retrieving goods in a container 264 in a warehouse system is described according to an aspect of the disclosed embodiment. The method includes the step of providing at least one storage level 130L having a storage passage 130A and a transport deck 130DC connecting the storage passage 130A (Figure 13, block 13100). At least one breakpack station 140 is provided (Figure 13, block 13110) and is connected to the transport deck 130DC so as to communicate with it. At least one goods sorting and container closing station 155 is provided (Figure 13, block 13120) and is connected to the transport deck 130DC so as to communicate with it by an asynchronous transport system (as described herein - see Figure 1G). The goods container 264 is transported by at least one autonomous guide vehicle 110 traveling along the transport deck 130DC from at least one break-pack station 140 to at least one goods sorting and container closing station 155 (Figure 13, block 13130), where the goods container 264 has break-pack goods BPG inside.

[0095] Referring to Figures 1A, 1G, 4-11D, and 14, a method for storing and retrieving goods BPG in containers 264 in a warehouse system is described according to an aspect of the disclosed embodiment. The method includes the step of providing a goods setting and container closing station 155 (Figure 14, block 14100). The goods setting and container closing station 155 includes a container setting device 420 and a container closing bay 430. The container setting device 420 has a frame 500 and a container platform 520, which is connected to the frame 500 by a link 525 at one end 521 of the container platform 520 and by a pivot 524F at the other end 522 of the container platform 520, where the pivot 524F is offset along the container platform 520 from the pivot joint 523 of the link 525 to the container platform 520. The goods setting device 520 also includes a drive unit 530 connected to the container platform 520. The container platform 520 is driven by a drive unit 530 in a periodic motion (Figure 14, block 14110). The container 264 is transported between the container leveling device 420 and the container closing bay 430 using a transport device 410 (Figure 14, block 14120).

[0096] Referring to Figures 1A, 1G, 4-11D, and 15, a method for transporting goods BPG in a container 264 within a warehouse system 100 for storage and retrieval of goods in the container 264 is described according to an aspect of the disclosed embodiment. The method includes the step of providing at least one goods sorting and container closing station 155 for the mixed product unit container 264 (Figure 15, block 15100). Opposing container lid manipulators 620, 1320, having opposing spiral guides 620A, 620B, 1320A, 1320B, engage with the respective lid portions 264L1, 264L2 of the mixed product unit container 264, guiding the closing movement of the respective lid portions 264L1, 264L2 from an open configuration to a closed configuration (Figure 15, block 15110), where the product setting and container closing station 155 has a container closing bay 430 including the opposing container lid manipulators 620, 1320.

[0097] According to one or more aspects of the disclosed embodiments, a product order fulfillment system for mixed product units held in a container for transport is provided. The system comprises a synchronous transport system forming a container transport path for transporting containers, the synchronous transport system having a container loading section arranged to communicate with an asynchronous container transport device for loading containers into the synchronous transport system; at least one container settling device configured to engage with a container transported along the container transport path and to rock the container in order to settle mixed product units in the container; and at least one container lid closing device configured to engage with the lid of a container transported along the container transport path and to close the lid, wherein the at least one container lid closing device and the at least one container settling device are connected in communication by the container transport path, the synchronous transport system includes an intervening switch selector, which controls the selection of the container transport path to orient the container towards at least one of the at least one container settling device, the at least one container lid closing device, and both the at least one container settling device and the at least one container lid closing device.

[0098] According to one or more aspects of the disclosed embodiments, the intervening switch selector comprises at least one container inspection station equipped with a sensor configured to detect the height of a mixed product unit in a container, and the intervening switch selector is configured to controllly select a container transport path based on the height, such as orienting the container to at least one of at least one container leveling device and bypassing the container leveling device.

[0099] According to one or more aspects of the disclosed embodiments, the intervening switch selector comprises at least one container inspection station and another container inspection station downstream along the container transport path, the other container inspection station comprising another sensor configured to detect the height of mixed product units in a container passing through the other container inspection station, and the intervening switch selector is configured to controllly select the container transport path based on the height, such as orienting the container to at least one of the container lid closing devices and bypassing the container lid closing devices.

[0100] According to one or more aspects of the disclosed embodiments, another container inspection station is located in the transport path between at least one container leveling device and at least one container lid closing device.

[0101] According to one or more embodiments of the disclosed embodiments, the synchronous transport device has an unloading unit configured to communicate with an asynchronous container transport device in order to unload containers with their lids closed from the synchronous transport device to an asynchronous transport device.

[0102] According to one or more aspects of the disclosed embodiments, the synchronous transport device is a grouping system comprising a plurality of grouping transport paths at different levels, where each transport path at each of the different levels directs the containers at each level to at least one of the following at each level: at least one container leveling device, at least one container lid closing device, and at least one of both the at least one container leveling device and the at least one container lid closing device.

[0103] According to one or more aspects of the disclosed embodiments, each respective level has an unloading section configured to communicate with an asynchronous container transporter in order to unload containers with their lids closed from a synchronous transporter to an asynchronous transporter at each respective level.

[0104] According to one or more aspects of the disclosed embodiments, the grouping system has a multi-level unloading section connected to a lift via an asynchronous container transport device.

[0105] According to one or more aspects of the disclosed embodiments, a method is provided for container transport of mixed product units in a product order fulfillment system, wherein the mixed product units are held in a container for transport. The method includes the steps of: transporting a container using a synchronous transport system that forms a container transport path for transporting containers, and loading the container into the synchronous transport system using a container loading section of the synchronous transport system that communicates with an asynchronous container transport device; engaging with the container transported along the container transport path using at least one container setting device for setting mixed product units inside the container, thereby causing the container to swing; engaging with the lid of the container transported along the container transport path using at least one container lid closing device, thereby closing the lid, wherein at least one container lid closing device and at least one container setting device are connected so as to communicate with each other by the container transport path; and controllingly selecting the container transport path using an intervening switch selector of the synchronous transport device so as to orient the container towards at least one of the at least one container setting device, at least one container lid closing device, and both the at least one container setting device and at least one container lid closing device.

[0106] According to one or more aspects of the disclosed embodiments, the method further includes the steps of detecting the height of a mixed product unit in a container using sensors at at least one container inspection station of an intervening switch selector, and using the intervening switch selector to controllly select a container transport path that orients the container to at least one of at least one container leveling device and bypasses the container leveling device based on the height.

[0107] According to one or more aspects of the disclosed embodiments, the method further includes the steps of: detecting the height of a mixed product unit in a container passing through another container inspection station using another sensor of an intervening switch selector at another container inspection station, wherein the other container inspection station is located downstream from at least one container inspection station along a container transport path; and using an intervening switch selector, controllingly selecting a container transport path to orient the container towards at least one of at least one container lid closing devices and to bypass the container lid closing devices, based on the height.

[0108] According to one or more aspects of the disclosed embodiments, another container inspection station is located in the transport path between at least one container leveling device and at least one container lid closing device.

[0109] According to one or more embodiments of the disclosed embodiments, the method further includes the step of unloading a container with its lid closed from a synchronous conveying device to an asynchronous conveying device using an unloading unit of a synchronous conveying device, wherein the unloading unit is in communication with an asynchronous container conveying device.

[0110] According to one or more embodiments of the disclosed embodiments, the synchronous transport device is a grouping system comprising a plurality of grouping transport paths at different levels, the method further comprising the step of using each transport path at each of the different levels to orient containers at each level toward at least one container leveling device, at least one container lid closing device, and at least one of both the at least one container leveling device and the at least one container lid closing device at each level.

[0111] According to one or more aspects of the disclosed embodiments, the method further includes the step of unloading containers with their lids closed from a synchronous transport device to an asynchronous transport device at each respective level, wherein each respective level has an unloading section communicating with an asynchronous container transport device.

[0112] According to one or more aspects of the disclosed embodiments, the grouping system has a multi-level unloading section connected to a lift via an asynchronous container transport device.

[0113] According to one or more aspects of the disclosed embodiments, a warehouse system is provided for storing and retrieving goods in containers. The warehouse system comprises at least one storage level having storage aisles and a transport deck connecting the storage aisles; at least one breakpack station connected to communicate with the transport deck; at least one goods sorting and container closing station connected to communicate with the transport deck by an asynchronous transport system; and at least one autonomous guide vehicle configured to travel along the transport deck and transport goods containers containing breakpacked goods from at least one breakpack station to at least one goods sorting and container closing station.

[0114] According to one or more aspects of the disclosed embodiments, the goods sorting and container closing station further comprises at least one autonomous guided vehicle interface adjacent to the transfer deck, the at least one autonomous guided vehicle interface configured to bring about the transfer of goods containers between the goods sorting and container closing station and at least one autonomous guided vehicle.

[0115] According to one or more aspects of the disclosed embodiments, each storage level comprises its own goods sorting and container closing station, and each goods sorting and container closing station forms a stack of goods sorting and container closing stations.

[0116] According to one or more aspects of the disclosed embodiments, at least one goods sorting and container closing station comprises an asynchronous transport system and a synchronous transport system configured to transport goods containers between the at least one goods sorting and container closing station.

[0117] According to one or more aspects of the disclosed embodiments, the synchronous transport system transports product containers to one or more container leveling devices and container closing bays.

[0118] According to one or more aspects of the disclosed embodiments, a warehouse system for storing and retrieving goods in containers is provided. The warehouse system comprises a goods setting and container closing station, the goods setting and container closing station being a container setting device, the container setting device having a frame, a container platform, the container platform being connected to the frame by a link at one end of the container platform and to the frame by a pivot at the other end of the container platform, the pivot being offset along the container platform from the pivot joint of the link to the container platform, and a drive unit connected to the container platform and configured to drive the container platform in periodic motion, a container closing bay, and a transport device connecting the container setting device and the container closing bay in a communicative manner.

[0119] According to one or more aspects of the disclosed embodiments, the container closing bay comprises at least one opposing container lid manipulator having opposing guides configured to engage with each lid portion of one of the product containers and to guide the closing movement of each lid portion from an open configuration to a closed configuration.

[0120] According to one or more aspects of the disclosed embodiments, at least one opposing container lid manipulator comprises opposing spiral guides on the receiving side, arranged to guide each lid portion into a semi-closed orientation as the product container is moving in a first direction.

[0121] According to one or more aspects of the disclosed embodiments, at least one opposing container lid manipulator includes opposing spiral guides on the outbound side, arranged to guide each lid portion from a semi-closed orientation to a closed orientation as the product container is moving in a second direction opposite to a first direction.

[0122] According to one or more aspects of the disclosed embodiments, the container closing bay comprises a double outbound opposing helical guide positioned along a second direction opposite to a first direction, thereby guiding the product container from a semi-closed orientation to a closed orientation by one of the outbound opposing helical guides engaging with the leading portion of each lid portion in a semi-closed orientation and the other outbound opposing helical guide engaging with the trailing portion of each lid portion in a semi-closed orientation.

[0123] According to one or more aspects of the disclosed embodiments, the container closure bay further includes a frame to which at least one opposing container lid manipulator is connected; lid supports movably connected to the frame and configured to hold each lid portion in a semi-closed orientation; and outbound lid manipulators movably connected to the frame and configured to engage with each lid portion to provide an interlock between each lid portion.

[0124] According to one or more aspects of the disclosed embodiments, the container closure bay comprises a goods container carrying surface and a drive section configured to alternately drive the goods container carrying surface in a first direction into the container closure bay and in a second direction out of the container closure bay, wherein the second direction is opposite to the first direction.

[0125] According to one or more aspects of the disclosed embodiments, the container stabilization device further comprises a container grip movably connected to a frame, the container grip being configured to grip one of the product containers so that one product container and the platform move as a unit.

[0126] According to one or more aspects of the disclosed embodiments, the drive unit is connected to a frame and comprises a drive device, a cam connected to the output of the drive device, and a connecting link connecting the cam to a container platform.

[0127] According to one or more aspects of the disclosed embodiments, a fulcrum forms a pivot joint of another link connecting the container platform to a frame, and a drive unit drives the container platform in a reciprocating motion, with each link constraining the reciprocating motion of its respective pivot joint and the container platform to movement along a multidimensional reciprocating path.

[0128] According to one or more aspects of the disclosed embodiments, a warehouse system is provided for storing and retrieving goods in containers. The warehouse system comprises at least one goods setting and container closing station for mixed product unit containers, the goods setting and container closing station comprising a container closing bay including an opposing container lid manipulator having opposing helical guides configured to engage with each lid portion of a mixed product unit container and guide the closing movement of each lid portion from an open configuration to a closed configuration.

[0129] According to one or more aspects of the disclosed embodiments, the warehouse system further comprises a transport device having an inbound interface station and an outbound interface station, wherein the inbound interface station is configured to bring in mixed product unit containers to at least one goods sorting and container closing station, and the outbound interface station is configured to bring out mixed product unit containers from at least one goods sorting and container closing station.

[0130] According to one or more aspects of the disclosed embodiments, the warehouse system further comprises a container settling device configured to grip and shake a mixed product unit container to bring the product units within the mixed product unit container to a state of order.

[0131] According to one or more aspects of the disclosed embodiments, the transport device is connected to a container leveling device and a container closing bay so as to be in communication with each other, and the container closing bay is located downstream of the container leveling device.

[0132] According to one or more aspects of the disclosed embodiments, the container setting device comprises a frame; a container platform, the container platform being connected to the frame by a link at one end of the container platform and to the frame by a pivot at the other end of the container platform, the pivot being offset along the container platform from the pivot joint of the link to the container platform; and a drive unit connected to the container platform and configured to drive the container platform in periodic motion.

[0133] According to one or more aspects of the disclosed embodiments, the container stabilization device further comprises a container grip movably connected to a frame, the container grip being configured to grip one of the product containers so that one product container and the platform move as a unit.

[0134] According to one or more aspects of the disclosed embodiments, the container leveling device further comprises a drive section connected to a frame, the drive section comprising a drive device, a cam connected to the output of the drive device, and a connecting link connecting the cam to a container platform.

[0135] According to one or more aspects of the disclosed embodiments, at least one opposing container lid manipulator comprises opposing spiral guides on the receiving side, arranged to guide each lid portion into a semi-closed orientation as the product container is moving in a first direction.

[0136] According to one or more aspects of the disclosed embodiments, at least one opposing container lid manipulator includes opposing spiral guides on the outbound side, arranged to guide each lid portion from a semi-closed orientation to a closed orientation as the product container is moving in a second direction opposite to a first direction.

[0137] According to one or more aspects of the disclosed embodiments, the container closing bay comprises a double outbound opposing helical guide positioned along a second direction opposite to a first direction, thereby guiding the product container from a semi-closed orientation to a closed orientation by one of the outbound opposing helical guides engaging with the leading portion of each lid portion in a semi-closed orientation and the other outbound opposing helical guide engaging with the trailing portion of each lid portion in a semi-closed orientation.

[0138] According to one or more aspects of the disclosed embodiments, the container closing bay further includes a frame to which at least one opposing container lid manipulator is connected; lid supports movably connected to the frame and configured to hold each lid portion in a semi-closed orientation; and outbound lid manipulators movably connected to the frame and configured to engage with each lid portion to provide an interlock between each lid portion.

[0139] According to one or more aspects of the disclosed embodiments, the container closure bay comprises a goods container carrying surface and a drive section configured to alternately drive the goods container carrying surface in a first direction into the container closure bay and in a second direction out of the container closure bay, wherein the second direction is opposite to the first direction.

[0140] According to one or more aspects of the disclosed embodiments, the warehouse system comprises stacked storage levels, each storage level comprising its own goods sorting and container closing station, and each goods sorting and container closing station forming a stack of goods sorting and container closing stations.

[0141] According to one or more embodiments of the disclosed embodiments, a method is provided for storing and retrieving goods in containers in a warehouse system. The method includes the steps of: providing at least one storage level having storage aisles and a transport deck connecting the storage aisles; providing at least one breakpack station connected to the transport deck in a manner that allows communication with the transport deck; providing at least one goods sorting and container closing station connected to the transport deck in a manner that allows communication with the transport deck by an asynchronous transport system; and transporting a goods container from at least one breakpack station to at least one goods sorting and container closing station using at least one autonomous guide vehicle traveling on the transport deck, wherein the goods container has breakpack goods inside.

[0142] According to one or more aspects of the disclosed embodiments, the method further includes the step of bringing about the transfer of a product container between the product sorting and container closing station and at least one autonomous guided vehicle interface of the product sorting and container closing station and at least one autonomous guided vehicle interface, wherein the at least one autonomous guided vehicle interface is adjacent to the transfer deck.

[0143] According to one or more aspects of the disclosed embodiments, each storage level comprises a product sorting and container closing station, where each product sorting and container closing station forms a stack of product sorting and container closing stations.

[0144] According to one or more aspects of the disclosed embodiments, the method further includes the step of transferring a product container between an asynchronous transport system and at least one product sorting and container closing station using a synchronous transport system of at least one product sorting and container closing station.

[0145] According to one or more aspects of the disclosed embodiments, the synchronous transport system transports product containers to one or more container leveling devices and container closing bays.

[0146] According to one or more aspects of the disclosed embodiments, a method is provided for storing and retrieving goods in containers in a warehouse system. The method includes the steps of providing a goods setting and container closing station, the goods setting and container closing station comprising: a container setting device, the container setting device comprising: a frame; a container platform, the container platform comprising: a

[0147] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using opposing guides of at least one opposing container lid manipulator of a container closing bay to engage with each lid portion of the container and to guide the closing movement of each lid portion from an open configuration to a closed configuration.

[0148] According to one or more embodiments of the disclosed embodiments, the method further includes the step of guiding each lid portion into a semi-closed orientation using opposing helical guides on the receiving side of at least one opposing container lid manipulator while the product container is moving in a first direction.

[0149] According to one or more embodiments of the disclosed embodiments, the method further includes the step of guiding each lid portion from a semi-closed orientation to a closed orientation using opposing helical guides on the outbound side of at least one opposing container lid manipulator, while the product container is moving in a second direction opposite to a first direction.

[0150] According to one or more aspects of the disclosed embodiments, the container closing bay comprises a double outbound opposing helical guides arranged along a second direction opposite to a first direction, the method further comprising the step of engaging the leading portion of each lid portion in a semi-closed orientation with one of the outbound opposing helical guides and engaging the trailing portion of each lid portion in a semi-closed orientation with the other outbound opposing helical guide, while the goods container is moving in the second direction, thereby guiding each lid portion from a semi-closed orientation to a closed orientation.

[0151] According to one or more aspects of the disclosed embodiments, the method further includes: providing a frame for a container closure bay to which at least one opposing container lid manipulator is connected; holding each lid portion in a semi-closed orientation using lid supports of the container closure bay, wherein the lid supports are movably connected to the frame; and engaging each lid portion using an outbound lid manipulator of the container closure bay, thereby interlocking each lid portion with respect to each other, wherein the outbound lid manipulator is movably connected to the frame.

[0152] According to one or more aspects of the disclosed embodiments, the method further includes the steps of providing a goods container carrying surface of a container closure bay, and driving the goods container carrying surface alternately in a first direction into the container closure bay and in a second direction out of the container closure bay using a drive section of the container closure bay, wherein the second direction is opposite to the first direction.

[0153] According to one or more aspects of the disclosed embodiments, the method further includes the step of gripping a container with a container grip of a container straightening device so that the product container and platform move as a unit, wherein the container grip is movably connected to a frame.

[0154] According to one or more aspects of the disclosed embodiments, the drive unit is connected to a frame and comprises a drive device, a cam connected to the output of the drive device, and a connecting link connecting the cam to a container platform.

[0155] According to one or more aspects of the disclosed embodiments, a fulcrum forms a pivot joint of another link connecting the container platform to a frame, and a drive unit drives the container platform in a reciprocating motion, with each link constraining the reciprocating motion of its respective pivot joint and the container platform to movement along a multidimensional reciprocating path.

[0156] According to one or more aspects of the disclosed embodiments, a method is provided for transporting goods in containers within a warehouse system for storing and retrieving goods in containers. The method includes the steps of: providing at least one goods sorting and container closing station for mixed product unit containers; and engaging each lid portion of a mixed product unit container with opposing helical guides and guiding the closing movement of each lid portion from an open configuration to a closed configuration, wherein the goods sorting and container closing station has a container closing bay including the opposing container lid manipulator.

[0157] According to one or more aspects of the disclosed embodiments, the method further includes the steps of: using an inbound interface station of the transport device to bring a mixed product unit container into storage to at least one product sorting and container closing station; and using an outbound interface station of the transport device to bring a mixed product unit container out of storage from at least one product sorting and container closing station.

[0158] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a container settling device to grip and shake a mixed product unit container to bring the product units within the mixed product unit container to a state.

[0159] According to one or more aspects of the disclosed embodiments, the transport device is connected to a container leveling device and a container closing bay so as to be in communication with each other, and the container closing bay is located downstream of the container leveling device.

[0160] According to one or more aspects of the disclosed embodiments, the method further includes providing a container settling device a frame and a container platform, wherein the container platform is connected to the frame by a link at one end of the container platform and to the frame by a pivot at the other end of the container platform, the pivot being offset along the container platform from the pivot joint of the link to the container platform; and driving the container platform in periodic motion using a drive unit connected to the container platform.

[0161] According to one or more embodiments of the disclosed embodiments, the method further includes the step of gripping a mixed product unit container with a container grip of a container straightening device so that the product container and platform move as a unit, wherein the container grip is movably connected to a frame.

[0162] According to one or more aspects of the disclosed embodiments, the method further includes the step of causing a mixed product unit container to oscillate using a drive section of a container settling device, the drive section comprising a drive device connected to a frame, a cam connected to the output of the drive device, and a connecting link connecting the cam to a container platform.

[0163] According to one or more embodiments of the disclosed embodiments, the method further includes the step of guiding each lid portion into a semi-closed orientation using opposing helical guides on the receiving side of at least one opposing container lid manipulator while the product container is moving in a first direction.

[0164] According to one or more embodiments of the disclosed embodiments, the method further includes the step of guiding each lid portion from a semi-closed orientation to a closed orientation using opposing helical guides on the outbound side of at least one opposing container lid manipulator, while the product container is moving in a second direction opposite to a first direction.

[0165] According to one or more aspects of the disclosed embodiments, the container closing bay comprises a double outbound opposing helical guides arranged along a second direction opposite to a first direction, the method further includes the step of guiding each lid portion from a semi-closed orientation to a closed orientation by engaging the leading portion of each lid portion in a semi-closed orientation with one of the outbound opposing helical guides and engaging the trailing portion of each lid portion in a semi-closed orientation with the other of the outbound opposing helical guides, while the goods container is moving in the second direction.

[0166] According to one or more aspects of the disclosed embodiments, the method further includes: providing a frame for a container closure bay to which at least one opposing container lid manipulator is connected; holding each lid portion in a semi-closed orientation using lid supports movably connected to the frame; and engaging each lid portion with an out-side lid manipulator movably connected to the frame to provide an interlock between the lid portions.

[0167] According to one or more embodiments of the disclosed embodiments, the method further includes the step of using a drive section of a container closure bay to alternately drive the goods container carrying surface of the container closure bay in a first direction into the container closure bay and in a second direction out of the container closure bay, wherein the second direction is opposite to the first direction.

[0168] According to one or more aspects of the disclosed embodiments, the warehouse system comprises stacked storage levels, each storage level comprising its own goods sorting and container closing station, and each goods sorting and container closing station forming a stack of goods sorting and container closing stations.

[0169] It should be understood that the foregoing description is merely illustrative of the aspects of the disclosed embodiments. Various substitutions and modifications can be attempted by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, the aspects of the disclosed embodiments are intended to encompass all such substitutions, modifications, and variations within the scope of any claims appended herein. Furthermore, the mere fact that different features are described in different dependent or independent claims does not imply that combinations of these features cannot be used to their advantage, or that such combinations remain within the scope of the disclosed embodiments.

Claims

1. A product order fulfillment system for mixed product units held in a container for transport, wherein the product order fulfillment system is A synchronous transport system that forms a container transport path for transporting the containers, wherein the synchronous transport system has a container loading section arranged to communicate with an asynchronous container transport device for loading the containers into the synchronous transport system, At least one container leveling device configured to engage with the container as it is transported along the container transport path and to shake the container in order to level the mixed product units within the container, The system includes at least one container lid closing device configured to engage with the lid of the container transported along the container transport path and close the lid, A product order fulfillment system in which the at least one container lid closing device and the at least one container setting device are connected in communication via the container transport path, and the synchronous transport device includes an intervening switch selector, the intervening switch selector controllably selects the container transport path to orient the container towards the at least one container setting device, the at least one container lid closing device, and at least one of both the at least one container setting device and the at least one container lid closing device.

2. The product order fulfillment system according to claim 1, wherein the intervening switch selector comprises at least one container inspection station equipped with a sensor configured to detect the height of the mixed product unit in the container, and the intervening switch selector is configured to controllly select the container transport path such that, based on the height, the container is directed to at least one of the at least one container leveling device and bypasses the container leveling device.

3. Product order fulfillment system according to claim 2, wherein the intervening switch selector comprises another container inspection station downstream from the at least one container inspection station along the container transport path, the other container inspection station comprises another sensor configured to detect the height of the mixed product unit in the container as it passes the other container inspection station, and the intervening switch selector is configured to controllly select the container transport path such that the container is directed towards at least one of the at least one container lid closing device and bypasses the container lid closing device, based on the height.

4. The product order fulfillment system according to claim 2, wherein another container inspection station is located in the transport path between the at least one container leveling device and the at least one container lid closing device.

5. The product order fulfillment system according to claim 1, wherein the synchronous transport device has an unloading unit configured to communicate with the asynchronous container transport device so as to unload the container with its lid closed from the synchronous transport device to the asynchronous transport device.

6. The product order fulfillment system according to claim 1, wherein the synchronous transport device is a grouping system comprising a plurality of grouping transport paths at different levels, and each transport path at each of the different levels directs the container at each level to at least one of the at least one container leveling device, the at least one container lid closing device, and at least one of both the at least one container leveling device and the at least one container lid closing device at each level.

7. The product order fulfillment system according to claim 6, wherein each level has an unloading section configured to communicate with an asynchronous container transport device so as to unload the container with its lid closed from the synchronous transport device to the asynchronous transport device at each level.

8. The product order fulfillment system according to claim 6, wherein the grouping system has a multi-level unloading section connected to a lift via the asynchronous container transport device.

9. A method for container transport in a product order fulfillment system for mixed product units, wherein the mixed product unit is held in a container for transport, and the method is The process includes transporting the container using a synchronous transport system that forms a container transport path for transporting the container, and loading the container into the synchronous transport system using a container loading section of the synchronous transport system that communicates with an asynchronous container transport device, A step of using at least one container leveling device to level the mixed product unit inside the container, engaging with the container as it is transported along the container transport path, and causing the container to shake. A step of closing the lid of a container transported along the container transport path by engaging it with at least one container lid closing device, wherein the at least one container lid closing device and the at least one container leveling device are connected so as to be able to communicate with each other by the container transport path. A method comprising the step of controllingly selecting the container transport path using an interposed switch selector of a synchronous transport device so as to orient the container toward the at least one container positioning device, the at least one container lid closing device, and at least one of both the at least one container positioning device and the at least one container lid closing device.

10. A step of detecting the height of the mixed product unit inside the container using a sensor of at least one container inspection station of the intervening switch selector, The method according to claim 9, further comprising the step of using the intervening switch selector to controllly select the container transport path so as to orient the container to at least one of the at least one container leveling device based on the height, and to bypass the container leveling device.

11. A step of detecting the height of the mixed product unit in the container passing through the intervening switch selector using another sensor at another container inspection station, wherein the other container inspection station is located downstream from at least one container inspection station along the container transport path, The method according to claim 10, further comprising the step of using the intervening switch selector to orient the container towards at least one of the at least one container lid closing device based on the height, and controllably selecting the container transport path so as to bypass the container lid closing device.

12. The method according to claim 10, wherein another container inspection station is located in the transport path between the at least one container leveling device and the at least one container lid closing device.

13. The method according to claim 9, further comprising the step of unloading the container with its lid closed from the synchronous conveying device to an asynchronous conveying device using the discharge section of the synchronous conveying device, wherein the discharge section is in communication with the asynchronous container conveying device.

14. The method according to claim 9, wherein the synchronous transport device is a grouping system having a plurality of grouping transport paths at different levels, and the method further includes the step of using each transport path at each of the different levels to orient the containers at each of the levels toward at least one container leveling device, at least one container lid closing device, and at least one of both the at least one container leveling device and the at least one container lid closing device at each of the levels.

15. The method according to claim 14, further comprising the step of unloading the containers with their lids closed from the synchronous transport device to an asynchronous transport device at each respective level, wherein each respective level has an unloading section that communicates with the asynchronous container transport device.

16. The method according to claim 14, wherein the grouping system has a multi-level unloading section connected to a lift via the asynchronous container transport device.

17. A warehouse system for storing and retrieving goods in a container, wherein the warehouse system is A storage level having a storage passage and a transport deck connecting the storage passage, At least one breakpack station connected to a transport deck in a manner that allows communication with it, An asynchronous transport system connects to the transport deck so as to communicate with at least one goods sorting and container closing station, A warehouse system comprising: at least one autonomous guide vehicle configured to travel on the transfer deck and transport a product container containing break-packed goods from the at least one break-pack station to the at least one product sorting and container closing station.

18. The warehouse system according to claim 1, wherein the goods sorting and container closing station further comprises at least one autonomous guided vehicle interface adjacent to the transport deck, and the at least one autonomous guided vehicle interface is configured to bring about the transfer of the goods containers between the goods sorting and container closing station and the at least one autonomous guided vehicle.

19. The warehouse system according to claim 17, wherein each storage level is equipped with its own product sorting and container closing station, and the respective product sorting and container closing stations form a stack of product sorting and container closing stations.

20. The warehouse system according to claim 17, wherein the at least one product sorting and container closing station comprises a synchronous transport system configured to transport the product containers between the asynchronous transport system and the at least one product sorting and container closing station.

21. The warehouse system according to claim 20, wherein the synchronous transport system transports the product containers to one or more container leveling devices and container closing bays.

22. A warehouse system for storing and retrieving goods in a container, wherein the warehouse system is It is equipped with a goods sorting and container closing station, and the goods sorting and container closing station is A container leveling device, wherein the container leveling device is Frame and, A container platform wherein the container platform is connected to the frame by a link at one end of the container platform, and connected to the frame by a pivot at the other end of the container platform, the pivot being offset along the container platform from the pivot joint of the link to the container platform, A container leveling device comprising: a drive unit connected to the container platform and configured to drive the container platform in periodic motion; Container closure bay and A warehouse system comprising a container arranging device and a transport device that connects the container closing bay in a manner that allows them to communicate with each other.

23. The warehouse system according to claim 22, wherein the container closing bay comprises at least one opposing container lid manipulator having opposing guides configured to engage with each lid portion of one of the product containers and to guide the closing movement of each lid portion from an open configuration to a closed configuration.

24. The warehouse system according to claim 23, wherein the at least one opposing container lid manipulator includes opposing spiral guides on the receiving side that are arranged to guide each lid portion into a semi-closed orientation when the product container is moving in a first direction.

25. The warehouse system according to claim 24, wherein the at least one opposing container lid manipulator includes opposing spiral guides on the outbound side, which are arranged to guide each lid portion from the semi-closed orientation to the closed orientation when the product container is moving in a second direction opposite to the first direction.

26. The warehouse system according to claim 24, wherein the container closing bay comprises a double outbound opposing helical guide arranged along a second direction opposite to the first direction, so that, as the product container is moving in the second direction, one of the outbound opposing helical guides engages with the leading portion of each lid in the semi-closed orientation, and the other outbound opposing helical guide engages with the trailing portion of each lid in the semi-closed orientation, thereby guiding each lid from the semi-closed orientation to the closed orientation.

27. The aforementioned container closing bay, The frame to which the at least one opposing container lid manipulator is connected, A lid support portion is movably connected to the frame and configured to hold each of the lid portions in a semi-closed orientation, The warehouse system according to claim 23, further comprising: an outbound lid manipulator movably connected to the frame and configured to engage with each of the lid portions to provide an interlock between the lid portions.

28. The aforementioned container closing bay, Product container transport surface, The warehouse system according to claim 22, comprising: a drive section configured to alternately drive the product container transport surface in a first direction into the container closure bay and in a second direction out of the container closure bay, wherein the second direction is opposite to the first direction.

29. The warehouse system according to claim 22, wherein the container positioning device further comprises a container grip movably connected to the frame, the container grip being configured to grip one of the product containers so that the product container and the platform move as a unit.

30. The warehouse system according to claim 22, wherein the drive unit is connected to the frame and comprises a drive device, a cam connected to the output section of the drive device, and a connecting link connecting the cam to the container platform.

31. The warehouse system according to claim 22, wherein the fulcrum forms a pivot joint of another link connecting the container platform to the frame, the drive unit drives the container platform in a reciprocating motion, and each link restricts the reciprocating motion of each pivot joint and the container platform to movement along a multidimensional reciprocating path.

32. A warehouse system for storing and retrieving goods in a container, wherein the warehouse system is The system comprises at least one product sorting and container closing station for mixed product unit containers, wherein the product sorting and container closing station is A warehouse system comprising a container closing bay including an opposing container lid manipulator having opposing spiral guides configured to engage with each lid portion of the mixed product unit container and to guide the closing movement of each lid portion from an open configuration to a closed configuration.

33. The warehouse system according to claim 32, further comprising a transport device having an inbound interface station and an outbound interface station, wherein the inbound interface station is configured to bring the mixed product unit container into storage to the at least one goods sorting and container closing station, and the outbound interface station is configured to bring the mixed product unit container out of storage from the at least one goods sorting and container closing station.

34. The warehouse system according to claim 33, further comprising a container leveling device configured to grip and shake the mixed product unit container to bring the product units within the mixed product unit container to a state.

35. The warehouse system according to claim 34, wherein the transport device is connected to the container leveling device and the container closing bay in a manner that allows communication between them, and the container closing bay is located downstream of the container leveling device.

36. The container leveling device, Frame and, A container platform wherein the container platform is connected to the frame by a link at one end of the container platform, and connected to the frame by a pivot at the other end of the container platform, the pivot being offset along the container platform from the pivot joint of the link to the container platform, The warehouse system according to claim 34, comprising: a drive unit connected to the container platform and configured to drive the container platform in periodic motion.

37. The warehouse system according to claim 36, wherein the container positioning device further comprises a container grip movably connected to the frame, the container grip being configured to grasp one of the product containers so that the product container and the platform move as a unit.

38. The warehouse system according to claim 34, wherein the container leveling device further comprises a drive section connected to the frame, the drive section comprising a drive device, a cam connected to the output of the drive device, and a connecting link connecting the cam to the container platform.

39. The warehouse system according to claim 32, wherein the at least one opposing container lid manipulator includes opposing spiral guides on the receiving side that are arranged to guide each lid portion into a semi-closed orientation when the product container is moving in a first direction.

40. The warehouse system according to claim 39, wherein the at least one opposing container lid manipulator includes opposing spiral guides on the outbound side, which are arranged to guide each lid portion from the semi-closed orientation to the closed orientation when the product container is moving in a second direction opposite to the first direction.

41. The warehouse system according to claim 39, wherein the container closing bay comprises a double outbound opposing helical guide arranged along a second direction opposite to the first direction, so that, as the product container is moving in the second direction, one of the outbound opposing helical guides engages with the leading portion of each lid in the semi-closed orientation, and the other outbound opposing helical guide engages with the trailing portion of each lid in the semi-closed orientation, thereby guiding each lid from the semi-closed orientation to the closed orientation.

42. The aforementioned container closing bay, The frame to which the at least one opposing container lid manipulator is connected, A lid support portion is movably connected to the frame and configured to hold each of the lid portions in a semi-closed orientation, The warehouse system according to claim 32, further comprising: an outbound lid manipulator movably connected to the frame and configured to engage with each of the lid portions to provide an interlock between the lid portions.

43. The aforementioned container closing bay, Product container transport surface, The warehouse system according to claim 32, comprising: a drive section configured to alternately drive the product container transport surface in a first direction into the container closure bay and in a second direction out of the container closure bay, wherein the second direction is opposite to the first direction.

44. The warehouse system according to claim 32, wherein the warehouse system comprises stacked storage levels, each storage level comprises its own product sorting and container closing station, and each of the product sorting and container closing stations forms a stacked group of product sorting and container closing stations.

45. A method for storing and retrieving goods in a container in a warehouse system, wherein the method is A step of providing at least one storage level having a storage passage and a transport deck connecting the storage passage, A step of providing at least one breakpack station connected to a transfer deck in a manner that allows communication with the transfer deck, A step of providing at least one product sorting and container closing station connected to the transfer deck via an asynchronous transport system, A method comprising the steps of transporting a product container from the at least one breakpack station to the at least one product sorting and container closing station using at least one autonomous guide vehicle traveling on the transport deck, wherein the product container has breakpacked goods inside.

46. The method according to claim 45, further comprising the step of bringing about the transfer of the product container between the product sorting and container closing station and the at least one autonomous guidance vehicle interface of the product sorting and container closing station, wherein the at least one autonomous guidance vehicle interface is adjacent to the transfer deck.

47. The method according to claim 45, wherein each storage level is provided with its own product sorting and container closing station, and the respective product sorting and container closing stations form a stack of product sorting and container closing stations.

48. The method according to claim 45, further comprising the step of transferring the product container between the asynchronous transport system and the at least one product sorting and container closing station using the synchronous transport system of the at least one product sorting and container closing station.

49. The method according to claim 48, wherein the synchronous transport system transports the product container to one or more container setting devices and container closing bays.

50. A method for storing and retrieving goods in a container in a warehouse system, wherein the method is A process of providing a product sorting and container closing station, wherein the product sorting and container closing station is A container leveling device, wherein the container leveling device is Frame and, A container platform wherein the container platform is connected to the frame by a link at one end of the container platform, and connected to the frame by a pivot at the other end of the container platform, the pivot being offset along the container platform from the pivot joint of the link to the container platform, A container leveling device having a drive unit connected to the container platform, A process comprising a container closing bay, The process of driving the container platform in periodic motion using the drive unit, A method comprising the step of transporting a container between a container stabilization device and a container closure bay using a transport device.

51. The method according to claim 50, further comprising the step of using opposing guides of at least one opposing container lid manipulator of the container closing bay to engage with each lid portion of the container and to guide the closing movement of each lid portion from an open configuration to a closed configuration.

52. The method according to claim 51, further comprising the step of guiding each of the lid portions to a semi-closed orientation using opposing spiral guides on the receiving side of at least one opposing container lid manipulator while the product container is moving in a first direction.

53. The method according to claim 52, further comprising the step of guiding each lid portion from the semi-closed orientation to the closed orientation using opposing spiral guides on the outbound side of at least one opposing container lid manipulator, while the product container is moving in a second direction opposite to the first direction.

54. The method according to claim 52, wherein the container closing bay comprises a double outbound opposing spiral guide arranged along a second direction opposite to the first direction, and the method further comprises the step of engaging the leading portion of each lid portion in the semi-closed orientation with one of the outbound opposing spiral guides, and engaging the trailing portion of each lid portion in the semi-closed orientation with the other of the outbound opposing spiral guides, while the product container is moving in the second direction, thereby guiding each lid portion from the semi-closed orientation to the closed orientation.

55. The steps include providing a frame for the container closing bay to which at least one opposing container lid manipulator is connected, A step of holding each of the lid portions in a semi-closed orientation using the lid support portion of the container closing bay, wherein the lid support portion is movably connected to the frame, The method according to claim 51, further comprising the steps of using an outbound lid manipulator of the container closing bay to engage with each of the lid portions and to interlock each of the lid portions with respect to each other, wherein the outbound lid manipulator is movably connected to the frame.

56. The process of providing a product container transport surface for the container closing bay, The method according to claim 50, further comprising the step of using the drive section of the container closing bay to alternately drive the product container transport surface in a first direction into the container closing bay and in a second direction out of the container closing bay, wherein the second direction is opposite to the first direction.

57. The method according to claim 50, further comprising the step of gripping a container using a container grip of a container straightening device so that the product container and the platform move as a unit, wherein the container grip is movably connected to the frame.

58. The warehouse system according to claim 50, wherein the drive unit is connected to the frame and comprises a drive device, a cam connected to the output section of the drive device, and a connecting link connecting the cam to the container platform.

59. The method according to claim 50, wherein the fulcrum forms a pivot joint of another link connecting the container platform to the frame, the drive unit drives the container platform in a reciprocating motion, and each link restricts the reciprocating motion of each pivot joint and the container platform to movement along a multidimensional reciprocating path.

60. A method for transporting goods in a container within a warehouse system for storing and retrieving the goods in the container, wherein the method is A process of providing at least one product sorting and container closing station for a mixed product unit container, A method comprising the steps of using opposing container lid manipulators having opposing spiral guides to engage with each lid portion of the mixed product unit container and to guide the closing movement of each lid portion from an open configuration to a closed configuration, wherein the product setting and container closing station has a container closing bay including the opposing container lid manipulators.

61. A process of using the loading interface station of the transport device to bring the mixed product unit container into storage at least one product sorting and container closing station, The method according to claim 60, further comprising the step of using the discharge interface station of the transport device to bring about the discharge transfer of the mixed product unit container from the at least one product sorting and container closing station.

62. The method according to claim 61, further comprising the step of using a container leveling device to grasp and shake the mixed product unit container to level the product units within the mixed product unit container.

63. The method according to claim 62, wherein the transport device is connected to the container leveling device and the container closing bay so as to be able to communicate with each other, and the container closing bay is positioned downstream of the container leveling device.

64. The container leveling device, Frame and, A container platform comprising the steps of providing a container platform wherein the container platform is connected to a frame by a link at one end of the container platform, and connected to the frame by a pivot at the other end of the container platform, and the pivot is offset along the container platform from the pivot joint of the link to the container platform, The method according to claim 62, further comprising the step of driving the container platform in a periodic motion using a drive unit connected to the container platform.

65. The method according to claim 64, further comprising the step of gripping the mixed product unit container with a container grip of the container straightening device so that the product container and the platform move as a unit, wherein the container grip is movably connected to the frame.

66. The method according to claim 62, further comprising the step of causing the mixed product unit container to oscillate using the drive section of the container leveling device, wherein the drive section is connected to the frame and comprises a drive device, a cam connected to the output of the drive device, and a connecting link connecting the cam to the container platform.

67. The method according to claim 60, further comprising the step of guiding each of the lid portions to a semi-closed orientation using opposing spiral guides on the receiving side of at least one opposing container lid manipulator while the product container is moving in a first direction.

68. The method according to claim 67, further comprising the step of guiding each lid portion from the semi-closed orientation to the closed orientation using opposing spiral guides on the outbound side of at least one opposing container lid manipulator, while the product container is moving in a second direction opposite to the first direction.

69. The method according to claim 67, wherein the container closing bay comprises a double outbound opposing spiral guide arranged along a second direction opposite to the first direction, and the method further includes the step of guiding each lid portion from the semi-closed orientation to the closed orientation by engaging the leading portion of each lid portion in the semi-closed orientation with one of the outbound opposing spiral guides and engaging the trailing portion of each lid portion in the semi-closed orientation with the other of the outbound opposing spiral guides, while the product container is moving in the second direction.

70. The steps include providing a frame for the container closing bay to which at least one opposing container lid manipulator is connected, A step of holding each of the lid portions in a semi-closed orientation using a lid support portion that is movably connected to the frame, The method according to claim 60, further comprising the step of using an outlet-side lid manipulator movably connected to the frame to engage with each of the lid portions and to cause interlocking of the lid portions with each other.

71. The method according to claim 60, further comprising the step of using the drive section of the container closing bay to alternately drive the product container transport surface of the container closing bay in a first direction into the container closing bay and in a second direction out of the container closing bay, wherein the second direction is opposite to the first direction.

72. The method according to claim 60, wherein the warehouse system comprises stacked storage levels, each storage level comprises its own product sorting and container closing station, and each of the product sorting and container closing stations forms a stacked group of product sorting and container closing stations.

Images