A warehouse system for storing and retrieving goods from containers.

Abstract

The automated product tote destacker tool comprises a frame with a coupling configured to fit the automated product tote destacker tool to the end of a robot so that the automated product tote destacker tool provides an end effector to the robot; a picking head array of tote picking heads movably connected to and supported from the frame, wherein the picking head array is configured to hold the tote array to the robot simultaneously, and each different tote of the tote array is held by a corresponding tote picking head different from each other tote picking head that holds each other different tote of the tote array, and each tote picking head has a tote grip that engages with the tote corresponding to the tote picking head; and a drive section connected to the frame and movably connected to each tote picking head to move the tote picking head as a unit.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is a non - provisional application of U.S. Provisional Patent Application No. 63 / 452,758, 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 particularly, to the conveyance and storage of articles within a material handling system.

Background Art

[0003] Brief Description of Related Developments 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 overall cost of the logistics chain. Conventional systems generally operate by storing product (e.g., supply) containers, where a supply container contains cases, packs, etc. that include common types of merchandise (also called products). 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 storage locations across a three-dimensional array of storage racks to workstations by unloading product / supply containers (each containing articles of one or more products of a common product type, i.e., each article of product in a product container is 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 a given workstation by the automated storage and retrieval system, and the various picked goods (common if a given order containing them is filled in this way) are placed into an order container. Such a workstation may be called a breakpack station, where product containers are "broken" and their contents, in whole or in part, may be placed into an order container or into what is called a breakpack storage container, for example, where the product container is not suitable for continuously holding the articles of the remaining product after the breakpack operation, and such remaining product (i.e., the remaining product in the "broken" product container) should be returned to storage locations across a three-dimensional array of storage racks by the automated storage and retrieval system. Generally, containers are manually stacked and separated for systemic execution and placed in breakpack stations via operators or automated guided vehicles. [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 1] This is a schematic diagram of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 2] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 3] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 4] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 5] 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 6] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 7] This is a schematic diagram of a portion of an automated storage and retrieval system according to an embodiment of the disclosed model. [Figure 8] This is a schematic diagram of a portion of the storage and retrieval system according to an embodiment of the disclosed model. [Figure 9] This is a schematic diagram of a portion of the storage and retrieval system according to an embodiment of the disclosed model. [Figure 10] This is a schematic diagram of a portion of the storage and retrieval system according to an embodiment of the disclosed model. [Figure 11] This is a schematic diagram of a portion of the storage and retrieval system according to an embodiment of the disclosed model. [Figure 12] This is a schematic diagram of a portion of the storage and retrieval system according to an embodiment of the disclosed model. [Figure 13] This is a schematic diagram of a transport vehicle according to an embodiment of the disclosed model. [Figure 14] This is a schematic diagram of a transport vehicle according to an embodiment of the disclosed model. [Figure 15] This is a schematic diagram of a partially closed configuration of a tote according to an embodiment of the disclosed model. [Figure 16A] This is a schematic diagram of a tote destacking system equipped with an automated product tote destacker tool for automated storage and retrieval systems according to an embodiment of the disclosed model. [Figure 16B] This is a schematic diagram of a tote destacking system equipped with an automated product tote destacker tool for automated storage and retrieval systems according to an embodiment of the disclosed model. [Figure 17] Figure 4 is a schematic diagram of various parts of the automated product tote destacker tool according to an embodiment of the disclosed model. [Figure 18] Figure 4 is a schematic diagram of various parts of the automated product tote destacker tool according to an embodiment of the disclosed model. [Figure 19] Figure 4 is a schematic diagram of various parts of the automated product tote destacker tool according to an embodiment of the disclosed model. [Figure 20] Figure 4 is a schematic diagram of various parts of the automated product tote destacker tool according to an embodiment of the disclosed model. [Figure 21] This is an illustrative flowchart of a method according to an embodiment of the disclosed features. [Figure 22] 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 are not stored (e.g., not included) in trays, tote bags 1510A-n, or on pallets. In other examples, a case unit is a case or unit of goods that are included in any suitable way, such as in trays, tote bags 1510A-n, containers (such as containers for broken-down case unit structures that are not suitable for transporting remaining goods as units), on pallets, etc. In yet another example, a case unit is a combination of included and not included articles. 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 removed from or placed on a pallet. According to aspects of the disclosed embodiments, a transport case for the case unit (e.g., a carton, barrel, box, crate, jug, or any other suitable device for holding the case unit) may have a variable size, be used to hold the case unit during transport, and be configured to be palletized for transport. For example, when a bundle or pallet of case units arrives at the storage and retrieval system 100, the contents of each pallet may be uniform (e.g., each pallet holds a predetermined number of the same items; i.e., one pallet holds soup and another pallet holds cereal), and when the pallet leaves the storage and retrieval system 100, the pallet may contain any suitable number and combination of different case units (e.g., a mixed pallet where each mixed pallet holds different types of case units).That is, the pallets hold combinations of soup and cereal, and it should be noted that these are provided to the 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 for 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 when 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 5 (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 5 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 10). The breakpack module 266 is configured to break down (one or more) product containers or case units CU (Figure 5) into breakpack product totes 1510A-n (also referred to herein as product containers or mixed product unit containers, see Figures 2 and 15) for order fulfillment. Throughout this specification, the term “tote” is used, but it should be noted that “tote” should be interpreted herein to include all kinds of totes, containers, boxes, buckets, cartons, crates, etc. A (one or more) breakpack merchandise tote 1510A-n (see brief Figure 15) is a container having, for illustrative purposes only (but the tote may have any suitable configuration), a bin section 264B having a bin opening 264OP and a bottom inner surface 264BS in which merchandise is placed, and lid sections 264L1, 264L2 attached to the bin section 264B by hinges, respectively. The lid sections 264L1, 264L2 are interlocking lid sections, each having an upper locking section and a lower locking section, which interlock with each other in a cam manner to maintain the lid sections 264L1, 264L2 in a closed configuration when closed. Here, merchandise is placed into the (one or more) breakpack merchandise tote 1510A-n by automation (as described herein) so that it can be loosely placed. To provide empty totes to the breakpack module 266, the automated storage and retrieval system 100 includes at least one tote destacking system 1000 (see, for example, Figures 1 and 16) that provides (one or more) breakpack merchandise totes 1510A-n to the breakpack module 266 to bring about the fulfillment of (one or more) breakpack merchandise totes 1510A-n.(One or more) tote destacking systems 1000 include a robot 999 having an automated product tote destacker tool 1050. The automated product tote destacker tool 1050, as further described herein, includes a frame 1100 having a connection 1110 configured to mate the automated product tote destacker tool 1050 to a robot end 999E of the robot 999 so that the automated product tote destacker tool 1050 provides an end effector for the robot 999 to denest (one or more) totes 1510A-n from stacks 1505A-n.

[0011] In some aspects, the automated storage and retrieval system 100 may include one or more each picking module that is substantially similar to those described in U.S. Patent No. 9,037,286, issued May 19, 2015 (the entire disclosure of which is incorporated herein by reference), (in addition to or instead of the break pack module 266), where the (one or more) break pack totes 1510A-n are filled by a human or robotic operator and the (one or more) break pack totes 1510A-n are carried from the (one or more) tote destacking systems 1000 to each picking module by a container bot 110 in a manner substantially similar to the methods described herein with respect to the break pack module 266.

[0012] A common level 130L of the automated storage and retrieval system 100 may contain one or more break pack modules 266 and one or more tote destacking systems 1000 for destacking (one or more) totes 1510A-n from stacks 1505A-n, where one or more levels of the automated storage and retrieval system 100 include at least one break pack module 266 and at least one tote destacking system 1000. The (one or more) tote destacking systems 1000 may be (one or more) plug-and-play modules 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) tote destacking systems 1000 may be connected to the container transfer deck 130DC or (one or more) picking (or picking) passage 130A of the automated storage and retrieval system 100. One or more tote destacking systems 1000 may be located at any appropriate number of stacked storage levels of the automated storage and retrieval system 100. Here, one or more tote destacking systems 1000 have a synchronous tote transporter or conveyor CTP (as described herein (see Figure 7)) that transports one or more totes 1510A-n from robot 999 (having an automated product tote destacker tool 1050) to an unloading interface station 1001. From the unloading interface station 1001, one or more totes 1510A-n are transported to a breakpack module 266 (or, for example, a breakpack putwall such as that described in U.S. Patent Application No. 17 / 657,705, filed April 1, 2022, titled “Warehousing System for Storing and Retrieving Goods in Containers,” the entire disclosure of which is incorporated herein by reference, to retrieve products from the “disassembled” case unit CU.Each tote conveyor CTP at each respective level 130L of the various levels 130L is directed towards the outfeed interface station 1001 with the (one or more) totes 1510A-n at each respective level 130L. As described herein, the outfeed interface station 1001 is configured to communicate with an asynchronous container conveyor (as shown in FIG. 7 as described herein) to offload the (one or more) totes 1510A-n from the tote conveyor CTP to the asynchronous conveyor at each respective level 130L. In one aspect, the tote conveyor CTP is in the form of a linear conveyor adapted to receive the (one or more) totes 1510A-n placed thereon by the system 1000. In another aspect (not shown), the tote conveyor CTP is replaced by an outfeed table or other means adapted to receive the (one or more) totes 1510A-n, such as directly onto an automated guided vehicle (AGV). In yet another aspect, two (or more) tote conveyor CTPs or other outfeed means are used.

[0013] The automated storage and retrieval system 100 may be configured via any suitable controller (e.g., a control server 120) to have selectable operating modes. In one operating mode, the automated storage and retrieval system 100 is configured to output product cases, containers, and / or case units to 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 break up product cases, product containers, and / or case units and output the breakpack product containers, product cases, containers, and / or case units to a palletizer, or in other embodiments, to re-input the remaining (one or more) breakpack (order) containers and / or product cases, containers, and / or case units (e.g., after being broken up) into the palletizer for later retrieval. At least one tote destacking system 1000 is configured to automatically separate stacks 1505A-n of totes 1510A-n before transport to one or more break pack modules 266 to be filled.

[0014] The controller 120 is configured, as can be understood, to bring about the operation of the container bot 110 and product bot 262 (both forming at least part of the asynchronous transport system) for assembling orders of breakpack goods BPG from supply container 265 into (one or more) breakpack goods totes 1510A-n (see also, for example, Figure 10) and the unloading of (one or more) breakpack goods totes 1510A-n via the container unloading station TS. For example, the controller 120 is configured to bring about the operation of (one or more) container bot 110 between at least the container storage position 130S, the breakpack operation station 140, and the (one or more) tote destacking systems 1000 arranged along the breakpack goods transport deck 130DG. As another example, the controller 120 is configured to cause the operation of (one or more) product bots 262 to sort the breakpack product BPGs into (one or more) corresponding breakpack product totes 1510A-n, for example, by unit / individual level classification, by transporting the breakpack product BPGs by the product bots 262 traveling on the product transfer deck 130DG. As a further example, the controller 120 is configured to cause the operation of the container bots 110 such that (one or more) container bots 110 access (one or more) corresponding empty breakpack goods totes 1510A-n from the unloading interface station 1001, transport (one or more) empty breakpack goods totes 1510A-n to and from (one or more) breakpack modules 266, for example via passage along the container transfer deck 130DC, or in other embodiments via passage along the bot lane adjacent to the put wall 263W (Figure 10), and after filling (one or more) totes 1510A-n, transport (one or more) container bots 110 to at least one of the container unloading / transfer station TS and corresponding storage positions 130S at the corresponding level 130L of the multi-level storage array.

[0015] Referring also to Figure 5, it should be noted that, for example, when incoming bundles or pallets (e.g., 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 (e.g., each pallet holds a predetermined number of the same items, i.e., one pallet holds soup and another pallet holds cereal). As can be understood, the cases in 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 (e.g., 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). The cases assembled on a single pallet may have different dimensions and / or different SKUs. In one aspect of the disclosed embodiments, the storage and retrieval system 100 may generally be configured to include an incoming section, a storage and sorting section (wherein one aspect, storage of goods is optional), and an outgoing section, as will be described in more detail below. As can be understood, in one aspect of the disclosed embodiments, for example, operating as a retail distribution center, the system 100 may be responsible for receiving uniform pallet loads of cases, unpacking the pallet goods, or separating cases from uniform pallet loads into independent case units that are processed individually by the system, retrieving 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.

[0016] 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 (e.g., utilizing buffer stations and interface stations), sorts them, for example, by 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 orders (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.

[0017] 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.

[0018] 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).

[0019] As described herein, the automated storage and retrieval system 100 includes an automated conveying system (e.g., a bot, a breakpack module, a tote destacking system 1000, and other suitable level conveying devices described herein) with at least one asynchronous conveying system for conveying cases / products at a given storage structure level 130L (e.g., level conveying). 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 conveying deck (also referred herein as a container conveying deck) 130DC connecting the storage passage 130A. At least one breakpack station 140 is connected so as to be able to communicate with the conveying deck 130DC. At least one tote destacking system 1000 is connected to a transport deck 130DC via an asynchronous transport system (as described herein), and at least one autonomous guide vehicle (also referred herein as a container bot) 110 (for example, of an asynchronous transport system) is configured to travel along the transport deck 130DC (as described herein) and transport (one or more) totes 1510A-n from at least one tote destacking system 1000 to at least one breakpack station 140.

[0020] As described herein, the storage and retrieval system 100 includes non-deterministic container bots 110 traveling along one or more physical paths of the storage and retrieval system to provide at least one level of asynchronous nature. At least another level of asynchronous nature 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, so as 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.

[0021] 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 remove 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 of the storage levels of the storage structure 130 and are separate from the transport deck 130DC on which they travel. 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 articles 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 5) 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 in U.S. Patent No. 9,856,083, which has been incorporated herein by reference in whole earlier.

[0022] Referring also to Figures 1, 6, 8, and 10, the storage structure 130 may include (one or more) container autonomous transport travel loops 233, 233A located at each level of the storage structure 130 (e.g., formed on and along the container transport deck 130DC). 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 10) and breakpack goods totes 1510A-n (empty or filled) (see Figure 10) 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, as described in U.S. Patent No. 9,856,083, which is incorporated herein by reference in its entirety, are accessible from the running surface or picking aisle level of a common picking aisle.

[0023] Each storage level 130L includes pick-face storage / hand-off spaces 130S (hereinafter referred to as storage spaces 130S or container storage positions 130S) arranged circumferentially along the container transport deck 130DC. 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 passage 130A (connected to the container transport 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 transport deck 130B. In one embodiment, the shelves of the rack modules RM are arranged as multi-level shelves distributed along the picking passage 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 (Figure 8) 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.

[0024] The container transfer deck 130DC is substantially open and configured for non-deterministic passage of container bots 110 along multiple travel lanes extending to 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 passages 130A at each storage level 130L, so as to travel along the picking passages, and accesses the storage spaces 130S arranged on rack shelves along each of the picking passages 130A (for example, the container bot 110 may have different sides when traveling through each picking passage 130A, for example, referring to Figure 13, 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 spaces 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 / or remove 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 spaces 130S.

[0025] As described above, and also with reference to Figure 8, 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).

[0026] 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 travel 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 travel, 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.

[0027] As described herein, one or more of the break pack modules 266 and / or (one or more) tote destacking systems 1000 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) container bot loading surfaces 266RS. A tote destacking system 1000 may be located on the side of a container transport deck 130DC where the picking passages 130A of a tote discharge 1001 adjacent to a bot lane of a put wall 263W (Figure 10) are located, and one or more picking passages 130A extend into the (one or more) tote destacking system 1000 to form (one or more) container bot loading surfaces. When container bot 110A delivers a supply container 265 from one or more tote destacking systems 1000 to a breakpack module 266AL or one or more breakpack totes 1510A-n, if a picking passage 133 extending to the breakpack module or a picking passage 134 extending to one or more tote destacking systems 1000 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 the supply container 265 from one or more tote destacking systems 1000 to the breakpack module 266AL or one or more breakpack totes 1510A-n.

[0028] 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.

[0029] 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 8, 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).

[0030] 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.

[0031] Referring to Figures 1, 8, and 10, 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 transport deck 130DC, where the mounting surface 2666RS is substantially similar to a portion of the container transport 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 in the breakpack module 266 as part of the container transport deck 130DC. In embodiments where the bot mounting surface 266RS is formed by (or is an extension of) a portion of the container transport deck 130DC, a single-path transport loop is illustrated in Figure 10 in the container transport deck 130D; 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 illustrated in Figure 8. For example, referring to Figure 12, the container bot travel surface 266RS is an open, non-deterministic travel surface with multiple inbound and outbound travel lanes. For example, there are multiple inbound travel lanes TL1, TL2, where travel lane TL2 is a bypass lane for traveling around obstacles on travel lane TL1 (or vice versa). Multiple outbound travel lanes TL3, TL4, TL5 may also exist. Here, travel lane TL5 defines column lane 130QL (Figure 10) for the container bot 110 at the breakpack goods interface 263, while travel lanes TL4 and TL5 may be used for exits from the breakpack module 266, with travel lane TL5 being a bypass for traveling around obstacles on travel lane TL4 (or vice versa).

[0032] 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.

[0033] 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 transport 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 transport deck 130DC) so that container bots 110 can travel along the non-deterministic container transport deck 130DC through the breakpack module 266 or move in and out of it, and at least one of the multiple travel lanes of the container transport deck 130DC defines a column lane 130QL (Figure 10) for container bots 110 at the breakpack goods interface 263. In one embodiment, the unloading interface station 1001 communicates with the container bot mounting surface 266RS so that (one or more) totes 1510A-n can be unloaded from the tote transport device CTP to the asynchronous transport device by an asynchronous container transport device (container bot 110).In other embodiments, the container bot loading surface 266RS includes a rail 1200S (see Figure 4) extending from the container transport deck 130DC in a manner similar to that of the picking aisle 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 10) for the container bot 110 at the breakpack goods interface 263. It should be noted that when the container bot loading surface 266RS is formed by the rail 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 to move between different travel sections (e.g., inbound and outbound) of the breakpack goods autonomous transport travel loop 234. As shown in Figure 10, 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 operating station 140 (and / or vice versa) and Break Pack product containers (also called Break Pack containers) 264 between Break Pack product interface 263 and container storage position 130S or lift 150A (and / or vice versa), respectively, along the travel loop 233 of the container bot travel surface 266RS. The travel loop 233 provides the container bot 110 with random access to any and each Break Pack product interface position 263L along the bot travel surface 266RS, where Break Pack product interface positions 263L form an asynchronous product distribution system.

[0034] 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 one or more breakpack product totes 1510A-n 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 (one or more) breakpack merchandise totes 1510A-n are placed to form a non-deterministic interface between the merchandise transfer deck 130DG and the container transfer deck 130DC.

[0035] 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 breakpack operating station 140 and integrated with goods (generally of the same type) in another (e.g., outgoing) supply container 265 or standardized container 265S at the breakpack goods interface 263, and the other supply container 265 or standardized container 265S is returned to storage. Generally, the supply containers 265 entering the breakpack module 266 are picked until empty, but only some (but not all) of the goods from the incoming supply containers may be decanted. Here, what is called an outbound (i.e., outbound from Breakpack Module 266) container 265 or standardized container 265S (tote, tray, etc.) may also be placed on the Breakpack product interface 263 by (one or more) container bots 110 in a manner similar to the method described herein with respect to (one or more) Breakpack product totes 1510A-n in order to facilitate the decanting process. In the decanting process, goods are taken out of a supply container 265 (which may be the original product / (one or more) product case packaging) at the Breakpack operation station 140 and integrated into an outbound supply container 265 or standardized container 265S located on the Breakpack product interface 263 (for example, having 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 if 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 into fewer supply containers 265 (which are then returned to the 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.).

[0036] 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 travel 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 one or more breakpack goods totes 1510A-n at the breakpack goods interface 263. A suitable example of the 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 autonomous transport travel loops 234 formed by the product deck 130DG have a plurality of travel lanes (see Figure 10) for the travel of product bots 262 along the (one or more) Breakpack autonomous transport travel loops 234 formed by the product 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 travel of product 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 autonomous transport travel loops 234 provide product bots 262 with random access to any and each of the Breakpack product interface positions 263L of the Breakpack product interface 263.

[0037] 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 or to the travel loops 234A-234E or an entrance (or on) ramp to the travel loops 234A-234E to bring about the transport of breakpack goods BPG to or from the breakpack goods tote 1510A-n (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 them). 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.

[0038] 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 “opposite 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.

[0039] Ramps 222, 222C, and 222R may be dynamically generated and brought about so that the ramp “rolls” along with 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., “rolling” ramps 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.

[0040] 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 the goods bot 262 or into one or more standardized containers 265S (totes, trays, etc.) and (one or more) breakpack goods totes 1510A-n 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 Break Pack operating 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, while 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 10 and 13, the Break Pack goods transfer deck 130DG merges with the Break Pack operating station 140 and the container transfer deck 130DC at a location separate from each access of the container transfer deck 130DC to the Break Pack operating station 140 (e.g., on a common support surface 140S) for the container bot 110 (e.g., at the Break Pack goods interface location 263L).

[0041] In one embodiment, also referring to Figure 11, 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 2 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.

[0042] 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 totes 1510A-n 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) for the purpose of filling loads according to a predetermined load filling order sequence, or for the purpose of fulfilling (one or more) individual fulfillment orders according to a predetermined individual fulfillment order sequence.

[0043] 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).

[0044] See also Figures 2 and 3, 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 bring about 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 (one or more) breakpack merchandise totes 1510A-n (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).

[0045] 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 side PAS1, PAS2 (see, for example, Figure 8) 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 2 and 3, 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).

[0046] 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 container support surface CUSP as shown in Figure 3) that facilitates the dynamic allocation of pick faces (e.g., supply containers 265) and / or (one or more) break pack merchandise totes 1510A-n 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 2 illustrates that the supply container 265 is stored in the side PAS2 of the picking aisle 130A, and that (one or more) breakpack merchandise totes 1510A-n are stored in the side PAS1 of the picking aisle 130A. In other embodiments, there may be combinations of supply container 265 and (one or both) breakpack merchandise totes 1510A-n stored in a common side PAS1, PAS2 of the picking aisle 130A (for example, one or both of side PAS1, PAS2) and / or combinations of supply container 265 and (one or more) breakpack merchandise totes 1510A-n stored on a common shelf surface.

[0047] In one embodiment, referring to Figures 4 and 14, 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 14 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 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.

[0048] Referring again to Figure 8, 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.) and (one or more) break pack goods totes 1510A-n are transferred on the container transfer deck 130DC between the lift load handling device LHD and the container bot 110. 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.) and (one or more) breakpack product totes 1510A-n from all interface stations TS to all storage spaces 130S corresponding to deck level 130L (and vice versa).

[0049] 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.) and (one or more) break pack goods totes 1510A-n between the container bot 110 and the lift 150 load handling device LHD, which will be 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 9, the interface station TS and / or buffer station BS include, in one embodiment, 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) in which the case unit or tote is transported to and 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.) and (one or more) break pack merchandise totes 1510A-n to a single level 130L of storage shelves, the interface station TS and / or buffer station BS also include a single level transfer rack shelf (much like the storage rack shelf of storage level 130L described above with respect to Figure 3, 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.) and (one or more) breakpack commodity totes 1510A-n 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 between the container bot 110 (as described herein) and the storage space 130S to which the case units and (one or more) breakpack commodity totes 1510A-n are transferred to and from the shelves. In other embodiments, the shelves may include a transfer arm for picking and positioning case units and (one or more) breakpack commodity totes 1510A-n from one or more loading handling device LHDs of the container bot 110 and lift 150. A suitable example of an interface station using an active transport arm is described, for example, in U.S. Patent No. 9,694,975, issued on July 4, 2017, the entire disclosure of which is incorporated herein by reference.

[0050] 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 3, 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.

[0051] As can be understood, referring to Figure 9, 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 1510A-n). As described above, each load in the multi-load station is either a single case unit / tote 1510A-n or a multi-case pick face (for example, having multiple case units / totes 1510A-n 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 1510A-n 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 1510A-n / breakpack goods containers and pick faces are temporarily stored when they are transferred between the container bot 110 and the load handling equipment LHD of the lift 150.

[0052] 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 8 and 9. 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 station includes a single level of transport rack shelves. The peripheral buffer station BS defines a buffer where case units / totes 1510A-n 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.

[0053] Still referring to Figures 8 and 9, in one embodiment, at least the interface station TS is located on an extension portion 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.

[0054] Referring to Figure 13, 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.

[0055] 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.

[0056] 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).

[0057] Still referring to Figure 13, 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 2, 9, and 11).

[0058] Still referring to Figure 13, 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 8-9), breakpack operation station 140 (see Figures 1 and 10), (one or more) tote destacking systems 1000, and / or breakpack product interface 263 (see Figures 1 and 10), 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 away from the base member 272. Referring again to Figure 3, 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.

[0059] Referring again to Figure 13, 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).

[0060] Referring here to Figures 1, 7, 8, 10, 12, and 16A-B, as described above, at least one tote destacking system 1000 can 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 tote destacking system 1000 may be located at one or more ends 130BE1, 130BE2 of the container transfer deck 130DC (in place of the storage rack module RM / picking passage 130A or lift 150A, 150B, or as an extension of one or more picking passages 130A, etc.) on the side of the bot lane adjacent to the put wall 263W, or at one or more sides 130BD1, 130BD2 of the container transfer deck 130DC. Each of the (one or more) tote destacking systems 1000 is a plug-and-play module such that the container transport deck 130DC is integrated with (or otherwise connected to) the container transport deck 130DC so as to be connected to at least one unloading interface station 1001 of the (one or more) tote destacking systems 1000, thereby enabling the container bot 110 to transport (one or more) breakpack totes 1510A-n from at least one tote destacking system 1000 to at least one breakpack station 266 via the container transport deck 130DC. In another embodiment, the unloading interface station 1001 interfaces with a container bot 110 traveling along a picking passage (see Figure 8) extending from the container transport deck 130DC, and is connected to the picking passage so as to communicate with it, thereby allowing the container bot 110 to transport (one or more) breakpack totes 1510A-n from at least one tote destacking system 1000 to at least one breakpack station 266 via the picking passage 130A.If the unloading interface station 1001 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 transport deck 130DC) where the container bot 110 can turn around to pick (one or more) breakpack totes 1510A-n from the unloading interface station 1001. If the unloading interface station 1001 interfaces with a container transport deck 130DC, the container transport deck may include a transport lane where the container bot 110 can "parallel park" adjacent to a given unloading interface station 1001 for the transport of (one or more) breakpack totes 1510A-n between the container bot 110 and the unloading interface station 1001.

[0061] As described herein, each tote destacking system 1000 includes a tote transporter CTP for transporting (one or more) totes 1510A-n from robot 999 to an unloading interface station 1001. The tote transporter CTP is configured to transport (one or more) breakpack commodity totes 1510A-n within each tote destacking system 1000. The tote transporter CTP includes a tote loading section 1010, which is at least partially formed by robot 999 and a stack 1505A-n of totes 1510A-n, and is configured to load (one or more) totes 1510A-n onto a tote transport path. The tote transporter CTP also includes an unloading interface station 1001, which is configured to communicate with an asynchronous container transporter (such as a container bot 110) to unload the totes 1510A-n and transport them to a breakpack module 266. The tote conveying device CTP is any suitable conveying device configured to convey (one or more) breakpack merchandise totes 1510A-n between the robot 999 and one or more of the unloading interface station 1001 and the reject / manual loading station 1007. The tote conveying device CTP 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 conveyance of (one or more) breakpack merchandise totes 1510A-n within each tote destacking system 1000. The robot 999 and the unloading interface station 1001 are connected in communicative manner by the tote conveying device CTP.

[0062] The tote transport device CTP may include at least one barcode scanner 1005 and a transport controller 1006 that controllably selects a container transport path to orient (one or more) totes 1510A-n to at least one of the unloading interface station 1001 and the reject / manual loading station 1007. The transport controller 1006 is communicably coupled to at least one barcode scanner 1005 configured to scan and track (one or more) totes 1510A. The transport controller 1006 is arranged to controllably select a tote transport path to orient (one or more) totes 1510A-n to at least one of the unloading interface station 1001 and the reject / manual loading station 1007 based on the scan (totes without barcodes or with damaged barcodes may be rejected). The transport controller 1006 may include another barcode scanner 1005A configured to scan and track (one or more) totes 1510A-n that are manually placed by the operator into the tote transport device CTP at the reject / manual loading station 1007. The transport controller 1006 may also include additional barcode scanners downstream or upstream of the reject / manual loading station 1007 to scan and track (one or more) totes 1510A-n.

[0063] Each of the (one or more) tote destacking systems 1000 includes at least an unloading interface station 1001, a tote transport device CTP, a robot 999, and stacks 1505A-n of (one or more) totes 1510A-n. The unloading interface station 1001 may be a passive interface having a structure substantially similar to those illustrated in Figures 3 and 9 with respect to storage shelves and buffers of rack module RM and transfer stations BS, TS, so that a container bot 110 can transport (one or more) breakpack totes 1510A-n between the unloading interface station 1001 and the transfer arm 110PA in substantially similar manner to the method described herein. The unloading interface station 1001 includes any suitable container drive device configured to move breakpack containers from each unloading interface station 1001 to the container bot 110 (e.g., a pusher, a drive-type spaced roller (spaced in a manner similar to slats 1210S, where the fingers of the transfer arm 110PA are inserted into the space between the rollers)). In other embodiments, the unloading interface station 1001 may be a passive interface such that a human operator initiates the transfer to the breakpack module 266.

[0064] Here, with reference to Figures 16A-20, a tote destacking system 1000 for separating (disconnecting) (one or more) totes 1510A-n from (one or more) stacks 1505A-n is described. As previously stated, the robot 999 is fitted with an arm end tool (end effector) in the form of an automated product tote destacker tool 1050, which is adapted to pick / separate (one or more) totes 1510A-n from stacks 1505A-n for transport to the break pack module 266 and transfer them to the tote transport device CTP. In this specification, the terms “robot” and “robot arm” are used interchangeably to mean a programmable system including a standard four-axis or six-axis industrial articulated arm that receives, controls, and moves an arm end tool. For example, the robot 999 could be a Comau NJ165-3.4 SH robot or any similar robot arm. Furthermore, although the robot is described and illustrated as a fixed articulated robotic arm, the robot may be any suitable robotic system, such as a gantry system or any other system. In another embodiment, the robotic arm and the tool 1050 may be integrated as a single device, providing the features of the combination of robot 999 and automated product tote destacker tool 1050. Robot 999 may include other well-known systems and components that enable its operation, such as robot controller 900. These systems and components are well-known in the art and are therefore not described in further detail herein for the sake of brevity.

[0065] In the tote destacking system 1000, the robot 999 is generally positioned adjacent to a tote unloading station 1600 which includes one or more tote arrays 1500 having one or more stacks 1505A-n of (one or more) totes 1510A-n positioned to be picked / stacked and separated by the robot 999 (although the tote array 1500 is illustrated as having four stacks, the tote array 1500 may have any appropriate number of stacks, which may or may not match the picking head array 1200 of the automated product tote destacking tool 1050 (i.e., the tote array 1500 may have more or fewer stacks than the picking head array 1200)). The tote array 1500 can be placed at the tote unloading station 1600 by, for example, a lift truck, an input tote conveyor, or any other suitable means (not shown) for transporting the array, which includes one or more stacks 1505A-n of one or more totes 1510A-n.

[0066] As described above, the automated product tote destacker tool 1050 includes a picking head array 1200 of tote picking heads 1250 that are movably connected to and dependent from the frame 1100. The picking head array 1200 is configured to stack and separate (i.e., include components) (one or more) totes 1510A-n one by one from each stack 1505A-n of the tote stacking array 1500 (i.e., from the top tote array to the bottom tote array of the tote stacking array 1500) using each respective tote picking head 1250A-n to stack and separate (one or more) totes 1510A-n. For example, the picking head array 1200 is configured to hold a single layer of the tote array 1500 for the robot 999 simultaneously. Each different tote 1510A-n of the tote array 1500 is held by a different corresponding picking head 1250A-n, each different picking head 1250A-n that holds each other different tote 1510A-n of the tote array 1500. As will become clearer from the following description, the system 1000 is not limited to stacking and separating “totes,” and as stated above, the term “tote” is used herein for convenience, but includes all kinds of stacked totes, containers, boxes, buckets, cartons, crates, etc. Also, although the system 1000 is described as picking from a stack 1505A-n of (one or more) totes 1510A-n that are tightly stacked vertically, it can be used to pick an array of (one or more) unstacked totes 1510A-n, such as the bottom layer.

[0067] Referring still at least to Figures 16-20, the picking head array 1200 includes tote picking heads 1250A-n that are movably connected to and supported from the frame 1100. For example, a drive section 1300 may be connected to (supported by) the frame 1100 and operably coupled to each picking head 1250A-n in order to drive the picking heads 1250A-n relative to the frame 1100. The picking heads 1250A-n are moved by the drive section 1300, either as a unit or individually, relative to the robot 999 in at least one direction LS and following the level of the corresponding tote 1510A-n. In one embodiment, the drive section 1300 may be a linear slide 1900 or linear joint having at least a drive motor 1901 and a guide rail 1902. The drive motor 1901 and guide rail 1902 are generally connected to the frame 1100 in any suitable manner (such as using fasteners). The picking head 1250A-n may be directly connected to each of the drive motor 1901 and guide rail 1902, or it may be connected to a carriage such that the drive motor 1901 drives the picking head 1250A-n linearly along the guide rail 1902 in at least one direction LS. In other embodiments, the drive section 1300 may be any other suitable drive device that moves the picking head 1250A-n in at least one direction LS relative to the robot 999. Furthermore, the drive section 1300 may include another drive device that moves the picking head 1250A-n in a direction different from at least one direction LS relative to the robot 999, such as pivoting or rotating the picking head 1250A-n.

[0068] Each picking head 1250A-n has its own tote grip 1260A-n that engages with and grips the corresponding tote 1510A-n. In the illustrated example, the automatic product tote destacker tool 1050 is shown having four picking heads 1250A-D, each having its own tote grip 1260A-D, but it should be noted that the automatic product tote destacker tool 1050 may include any number of picking heads 1250A-n, each having any number of tote grips 1260A-n. Furthermore, the automated product tote destacker tool 1050 functions regardless of whether the tote array 1500 contains one stack, four stacks, or any number of stacks, and whether that number matches the picking head array 1200 of the automated product tote destacker tool 1050 (i.e., the number of stacks in the tote array 1500 may be greater or less than the picking head array 1200, and the picking head array 1200 still picks the top tote of the stacks that the picking head array accesses). In one embodiment, the tote grip 1260A-n is an active grip positioned to capture and grip the corresponding tote 1510A-n onto the corresponding picking head 1250A-n. While the tote grip 1260A-n is generally exemplified as a vacuum gripper, the grip may be provided by any suitable means, such as a pneumatic gripper, a hydraulic gripper, an adaptive gripper, or a combination of various types of grippers. In embodiments where the tote grip 1260A-n is a vacuum gripper, the tote grip 1260A-n may be a dispersed grip (i.e., multiple grip contacts 1265A1-nm are distributed around the picking head 1250A-n to provide a dispersed grip). The multiple grip contacts 1265A1-nm are configured to engage with the corresponding tote 1510A-n gripped by the picking head 1250A-n. For example, the grip contacts 1265A1-nm are elastic follow-up suction cups with bellows to adapt to (one or more) non-flat or inclined tote 1510A-n.It should be noted that in the illustrated example, the picking heads 1250A-D are illustrated as having toe grips 1260A-D, each with four grip contacts 1265A1-D4, but the automatic product tote destacker tool 1050 may include any number of tote grips, each having any number of grip contacts (including fewer than four contacts, such as three, two, or one contact).

[0069] When in operation, the tote grip 1260A-n actively generates an upward gripping force GF (Figure 19) on the tote 1510A-n, with the grip contact 1265A1-nm seated on the internal bottom surface 264BS (Figure 15) of the gripped tote 1510A-n, causing tote picking and lifting the corresponding tote 1510A-n from the stack 1505A-n. In one embodiment, the multiple grip contacts 1265A1-nm of the picking head 1250A-n are configured to freely lift the corresponding tote 1510A-n from the stack 1505A-n when at least one of the multiple grip contacts 1265A1-nm of the picking head 1250A-n is not operational (i.e., each picking head 1250A-n grips and picks a tote independently of other picking heads so that if one picking head 1250A-n is not operational or is operating when there is no corresponding stack of totes in the tote stack array, or if a picking head fails to capture a tote due to interference from tote stacking, the other picking heads 1250A-n can still pick their respective totes). As described above, each grip contact 1265A1-nm of the tote grip 1260A-n is elastically conformed and positioned to seat on the internal bottom surface 264BS (Figure 15) of the tote 1510A-n, where the picking head 1250A-n accesses the tote 1510A-n through the opening 264OP of the tote 1510A-n.

[0070] In one embodiment, the tote grip 1260A-n is a vacuum grip generated by a venturi 1261 that provides robust metered-controlled suction (vacuum) for gripping the corresponding tote 1510A-n. The venturi suction is resistant to a decrease in suction force due to clogging such as debris and remnants in the tote. When the active grip is metered-controlled, the tote 1510A-n and the tote grip 1260A-n are configured to automatically detach when the picking head 1250A-n begins to tot-pick more than one tote 1510A-n (i.e., if two totes are picked in one picking (due to nesting adhesion), the tote grip will automatically detach from the tote and may be indicated as a picking failure). Automatic detachment occurs when the weight of the two totes exceeds the picking suction force of the picking head (e.g., via the venturi vacuum). For each tote picking from stack 1505A-n of totes 1510A-n, the picking head 1250A-n is metered (having a configured tote picking meter) so that, throughout approximately the entire destacking picking by the automatic product tote destacker tool 1050 which separates the stack 1505A-n of totes 1510A-n from the top tote 1510A-n to the bottom tote 1510A-n of the stack 1505A-n. In one embodiment, each separate picking head 1250A-n is metered (having a configured tote picking meter) such that each separate picking head 1250A-n brings tote picking from stacked totes 1510A-n individually, which are brought by the picking head array 1200 almost simultaneously, and the stacks 1505A-n of totes 1510A-n are stacked and separated almost simultaneously by the automatic product tote destacker tool 1050, and each separate picking head 1250A-n separately grasps only the corresponding tote from each separate picking head 1250A-n.Due to the picking head's weighing configuration, when a picking head 1250A-n begins to tote-pick more than one tote 1510A-n from a stack 1505A-n of totes 1510A-n, it results in the automatic detachment of the tote from the tote grip 1260A-n of the picking head 1250A-n, thereby ensuring that each picking head 1250A-n that performs tote picking grasps only the corresponding tote 1510A-n and separates the stack 1505A-n.

[0071] Referring to Figures 18-20, the automated product tote destacker tool 1050 further includes a first sensor system 1270 having one or more sensors 1275 positioned relative to the picking head array 1200 so as to be positioned above the tote array 1500 during picking of (one or more) totes 1510A-n. The one or more sensors 1275 are generally positioned to determine the bottom 264BS of the corresponding tote 1510A-n within the stack 1505A-n. For example, the sensor system 1270 may include any suitable vertical distance sensors positioned so that the tote array 1500 is within the field of view of the sensor 1275 (for example, in the case of an imaging sensor) or within the electromagnetic beam (for example, in the case of a reflected beam sensor). The first sensor system 1270 is not limited to being fixed to the frame 1100 above the tote unloading station 1600 and may be positioned in any suitable way to determine the vertical distance between the picking head array 1200 and the tote array 1500.

[0072] Sensor 1275 is configured to detect stacks 1505A-n of totes 1510A-n and determine one or more of the following: the height of the stacks 1505A-n, the distance from the stacks 1505A-n to the picking head array 1200, the distance from the picking head array to the bottom of the top tote 1510A-n, whether one stack 1505A-n contains more totes than another stack 1505A-n, or any other suitable vertical distances to assist in picking (one or more) totes 1510A-n from the stacks 1505A-n. For example, the first sensor system 1270 is positioned to acquire sufficient mapping data to determine the vertical orientation of the tote array 1500, for example, mapped from above. Sensor 1275 could be any suitable sensor such as ultrasonic, IR, LIDAR, reflective, or optical to capture the map data. The terms “map” or “mapped data” in this specification include any kind of data that forms a 2D or 3D representation of one or more totes, including conventional two-dimensional (2D) or three-dimensional (3D) grayscale or color images, depth maps, terrain images, height data, etc. Maps or depth values ​​obtained from the sensor system can be used to evaluate, verify, and / or correct the gripping points of totes 1510A-n on selected layers for the corresponding picking heads 1250A-n of the picking head array 1200. The robot 999 is configured to position the sensor 1275 on the tote array 1500 to determine, for example, the depth of one or more totes 1510A-n and the height of the stack 1505A-n. This determination is generally made before one or more first totes 1510A-n are grasped and picked, but may be made at any point between picking until the entire tote array 1500 has been processed. This generates a dynamic depth map for the topmost tote 1510A-n (one or more) in the tote array 1500, which is used by the controller 900 to determine, for example, the coordinates / position / orientation of the topmost tote 1510A-n (one or more).

[0073] Sensor 1275 is connected to a controller 900 configured for the transfer of captured map data between Sensor 1275 and the controller 900. The controller 900 is configured or programmed to analyze the map acquired by the first sensor system 1270 and analyze its properties to determine the coordinates of (one or more) individual upper tote An within (one or more) stacks 1505A-n. Examples of properties analyzed by the controller 900 include the depth of (one or more) tote 1510A-n, the height of (one or more) stacks 1505A-n, and the number of (one or more) stacks 1505A-n. The controller 900 may be wired or wirelessly connected to a robot 999 and configured to send the map to it to bring up the picking of the upper layers of (one or more) tote 1510A-n. The term "controller" should be understood as one or more electronic devices, such as one or more computers, processors, microcontrollers, etc., which are composed of components and / or programmed with instructions that produce one or more functions, in order to bring about the picking / separation of (one or more) Tote 1510A-n.

[0074] The controller 900 may be programmed to request a new acquisition by the first sensor system 1270 according to predetermined criteria such as the arrival of a new tote array at the tote unloading station 1600, a problematic scan, or a picking failure. For example, two side-by-side stacks 1505A-n of (one or more) totes 1510A-n within tote array 1500 are mapped by the first sensor system 1270. The controller 900 is configured to evaluate array 1500 in such cases and instruct the robot 999 to pick (one or more) totes 1510A-n. If picking fails, the controller 900 may be programmed to request a new acquisition by the first sensor system 1270, for example, based on a non-operating picking head, otherwise it may be difficult to identify and pick (one or more) the next totes 1510A-n.

[0075] In one embodiment, the picking head 1250A-n includes a second sensor system 1280 having one or more range sensors 1285. The second sensor system 1280 may cooperate with the first sensor system to map (one or more) totes 1510A-n to (one or more) through the tote opening 264OP before or immediately before insertion of the picking head 1250A-n into the tote 1510A-n. The map detects and identifies boundaries such as the sides 264S, edges 264E, bottom 264BS, and orientation of the tote. The second sensor system 1280 includes any suitable range sensor, such as ultrasonic, IR proximity, laser, or optical, to determine the position and orientation of (one or more) totes 1510A-n before they are picked and placed in the tote transport device CTP (Figure 7). In one embodiment, the second sensor system 1280 is generally positioned on the bottom surface 1299 of each picking head 1250A-n (i.e., the surface facing the tote array 1500) and oriented to map (one or more) totes 1510A-n before or immediately before insertion into the totes 1510A-n. As previously stated, one or more range sensors 1285 are positioned for detection of at least one of the side 264S, edge 264E, and opening 264OP (Figure 15) of the corresponding tote 1510A-n in the stack 1505A-n. In some embodiments, the sensor system 1280 also confirms that (one or more) totes 1510A-n have been picked by the automated product tote destacker tool 1050.

[0076] The sensor system 1280 may include any suitable range sensor positioned such that the tote array 1500 is within the field of view of the sensor 1285 (for example, in the case of an imaging sensor) or within the electromagnetic beam (for example, in the case of a reflected beam sensor). The second sensor system 1280 is not limited to being fixed to the bottom surface 1299 of each picking head 1250A-n, and may be positioned in any suitable manner to determine the range between the picking head array 1200 and the tote array 1500. In one embodiment, the second sensor system 1280 may include a cover (such as a bracket 1290) to protect the sensor in the event of a collision with a tote, for example.

[0077] For example, each picking head 1250A-n accesses a different stack 1505A-n approximately simultaneously, so as the picking head array 1200 accesses the tote array 1500 of stack 1505A-n, and each different picking head 1250A-n enters the tote 1510A-n corresponding to each of the other different picking heads 1250A-n of the picking head array 1200, picks a tote 1510A-n from each stack 1505A-n of the tote array 1500, captures it, and tote picks it. In general, the second sensor system 1280 determines the orientation and position of each corresponding tote 1510A-n relative to the picking head array 1200, so that the robot 999 transports the corresponding tote 1510A-n to the tote transport device CTP (Figure 7) in a predetermined manner, thereby generating a flow of empty tote 1510A-n aligned in a desired orientation on the tote transport device CTP.

[0078] The second sensor system 1280 is connected to the controller 900 by wire or wirelessly and is configured for transferring acquired map data to the controller 900. Once the controller 900 determines the position of (one or more) totes 1510A-n relative to the picking head array 1200, the controller 900 instructs the robot 999 to issue a movement displacement command to precisely position and orient the picking head array 1200 above the tote array 1500.

[0079] Referring also to Figure 22, a flowchart of the tote-picking method 2000 is described in more detail here, with reference to the operation of system 1000.

[0080] In block 2001, an array 1500 loaded with stacks 1505A-n of (one or more) totes 1510A-n is transferred to a tote unloading station 1600 next to robot 999. A first sensor 1270 maps (one or more) upper totes 1510A-n within the stacks 1505A-n, and more specifically, obtains a depth map of (one or more) upper totes 1510A-n (block 2002). In addition, a second sensor 1280 may measure measurements of the tote array 1500 to detect the edges 264E, sides 264S, and openings 264OP of the corresponding totes 1510A-n. In step 2003, the controller 900 utilizes the depth map to determine the next (one or more) tote 1510A-n to be picked / separated.

[0081] The controller 900 selects the highest tote 1510A-n (one or more), or if all upper tote 1510A-n (one or more) are at the same depth, the controller instructs the robot to pick the upper array of tote 1510A-n (one or more) (block 2003). The uppermost layer is determined using a bottom detection method. Instead of, or in addition to, such a method, if the depth is not determined, the edges 264E and sides 264S of tote 1510A-n (one or more) may be detected.

[0082] Subsequently, the controller 900 sends a command to the robot 999 (block 2004), and the robot 999 then uses the picking head array 1200 of the destacker tool 1050 to grasp one corresponding tote 1510A-n from each corresponding stack 1505A-n of the tote array 1500 (see Figure 16B), and moves the tote array to the tote loading unit 1010 (block 2005) (see Figure 2).

[0083] If tote 1510A-n cannot be identified in process 2003, stack 1505A-n is considered empty (block 2007), and system 1000 waits for the arrival of a new tote array 1500 having stack 1505A-n of (one or more) tote 1510A-n (block 2008).

[0084] In block 2006, map data is acquired by the second sensor system 1280 and sent to the controller 900, which helps determine the position and orientation of one or more totes 1510A-n relative to the picking head array 1200. The controller 900 uses this information to determine the amount of displacement required by the robot 999 to pick one or more totes 1510A-n.

[0085] Each time an array of (one or more) totes 1510A-n is moved on the tote transporter CTP, the method proceeds to block 2002, where the controller 900 determines whether tote array 1500 is empty. If it is empty, it waits for a newly loaded tote array 1500. Otherwise, the method returns to block 2003. For example, stack 1505A-n is determined to be empty if its greatest depth is equal to a known distance to the bottom of stack 1505A-n.

[0086] It should be noted that many other modifications can be made to the tote picking system 1000 and method described above in this specification and illustrated in the accompanying drawings. For example, two robotic arms can be used, for example, with two or more tote conveying devices (CTPs), in order to increase the production speed.

[0087] According to one aspect of the disclosed embodiments, an automated product tote destacker tool is provided. The automated product tote destacker tool comprises a frame having a coupling configured to fit the automated product tote destacker tool to a robot end so that the automated product tote destacker tool provides an end effector to the robot, and a picking head array of tote picking heads movably connected to and supported from the frame, wherein the picking head array is configured to simultaneously hold the tote array to the robot, with each different tote in the tote array being held by a corresponding tote picking head different from each other tote picking head that holds each other different tote in the tote array, and each tote picking head is a tote picking head The system includes a picking head array having toe grips that engage with totes corresponding to the totes, and a drive section connected to a frame, the drive section being operably connected to each tote picking head so as to move the tote picking head as a unit relative to the frame in accordance with the level of the corresponding totes, and the tote picking heads are weigh-controlled so that, with respect to each tote picking from the stack of totes, the tote picking heads are weigh-controlled so as to automatically and repeatedly pick only the corresponding totes from the stack throughout substantially the entire stack separation picking by an automated product tote destacker tool that separates the stack of totes from the top tote to the bottom tote of the stack.

[0088] According to one aspect of the disclosed embodiment, the weighing configuration of the picking head results in automatic detachment of the tote from the tote grip of the tote picking head when the tote picking head begins to tot-pick more than one tote from a stack of totes, thereby ensuring that each tote picking head that initiates tote picking grasps only the corresponding tote and separates the stacks.

[0089] According to one aspect of the disclosed embodiment, the tote grip is an active grip positioned to capture and grasp a corresponding tote on a tote picking head, and the active grip is metering-controlled such that the tote and grip separate when the tote picking head begins to tote-pick more than one tote.

[0090] According to one aspect of the disclosed embodiment, the tote grips are distributed to form a plurality of grip contacts with respect to each tote picking head, which are configured to engage with the corresponding tote gripped by the tote picking head.

[0091] According to one aspect of the disclosed embodiment, each grip contact of the tote grip is arranged to elastically conform and seat on the inner bottom surface of the tote, and the tote picking head accesses the tote through the opening of the tote.

[0092] According to one aspect of the disclosed embodiment, each grip contact actively generates an upward gripping force on the tote when in operation, with the grip contact seated on the inner bottom surface of the gripped tote.

[0093] According to one aspect of the disclosed embodiment, the tote grip is configured to grip the corresponding tote on the tote picking head by an upward force, thereby causing tote picking and lifting the corresponding tote free from the stack, when at least one of the plurality of grip contacts of the tote picking head is not operational.

[0094] According to one aspect of the disclosed embodiment, the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

[0095] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding tote in the stack.

[0096] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding totes in the stack.

[0097] According to one aspect of the disclosed embodiment, each tote picking head of the picking head array has a corresponding one of at least one distance sensor positioned such that the position of the picking head array is determined relative to a group of stacks, each tote picking head accesses a different stack substantially simultaneously so that the picking head array accesses a group of stacks, and each different tote picking head enters, captures, and picks a tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking a tote from each stack of the group.

[0098] According to one aspect of the disclosed embodiments, an automated product tote destacker tool is provided. The automated product tote destacker tool includes a frame with a coupling configured to fit the automated product tote destacker tool to a robot end so that the automated product tote destacker tool provides an end effector to the robot, and a picking head array of tote picking heads movably connected to and supported from the frame, wherein the picking head array is configured to simultaneously hold the tote array to the robot, with each different tote in the tote array being held by a corresponding tote picking head different from each other tote picking head that holds each other different tote in the tote array, and each tote picking head is The system includes a picking head array having toe grips that engage with totes corresponding to the picking heads, wherein each toe picking head is movably connected to a frame so that the toe picking heads move as a unit relative to the robot in accordance with the level of the corresponding totes, and the toe picking heads are weigh-controlled so that each separate toe picking head, each bringing toe picking from the stacked totes, is brought by the picking head array substantially simultaneously, and the stack of totes is stacked and separated substantially simultaneously by an automated product tote destacker tool, and each toe picking head separately grasps only the corresponding tote from each toe picking head.

[0099] According to one aspect of the disclosed embodiment, a drive section is supported from the frame and operably connected to each tote-picking head, thereby acting the tote-picking heads in at least one direction relative to the robot.

[0100] According to one aspect of the disclosed embodiment, with respect to each tote picking from a stack of totes, the tote picking head is weighed and controlled so as to automatically and repeatedly pick only the corresponding totes from the stack, throughout substantially the entire stack separation picking by an automated product tote destacker tool that separates the stack of totes from the top tote to the bottom tote of the stack.

[0101] According to one aspect of the disclosed embodiment, the weighing configuration of the picking head results in automatic detachment of the tote from the tote grip of the tote picking head when the tote picking head begins to tot-pick more than one tote from a stack of totes, thereby ensuring that each tote picking head that brings up tote picking grasps only the corresponding tote and separates the stacks.

[0102] According to one aspect of the disclosed embodiment, the tote grip is an active grip positioned to capture and grasp a corresponding tote on a tote picking head, and the active grip is metered and controlled so that the tote and grip separate when the tote picking head begins to tote picking one or more totes.

[0103] According to one aspect of the disclosed embodiment, the tote grips are distributed to form a plurality of grip contacts with respect to each tote picking head, which are configured to engage with the corresponding tote gripped by the tote picking head.

[0104] According to one aspect of the disclosed embodiment, each grip contact of the tote grip is arranged to elastically conform and seat on the inner bottom surface of the tote, and the tote picking head accesses the tote through the opening of the tote.

[0105] According to one aspect of the disclosed embodiment, each grip contact actively generates an upward gripping force on the tote when in operation, with the grip contact seated on the inner bottom surface of the gripped tote.

[0106] According to one aspect of the disclosed embodiment, the tote grip is configured to grip the corresponding tote on the tote picking head by an upward force, thereby causing tote picking and lifting the corresponding tote free from the stack, while at least one of the plurality of grip contacts of the tote picking head is not operating.

[0107] According to one aspect of the disclosed embodiment, the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

[0108] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding tote in the stack.

[0109] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding totes in the stack.

[0110] According to one aspect of the disclosed embodiment, each tote picking head of the picking head array has a corresponding one of at least one distance sensor positioned such that the position of the picking head array is determined relative to a group of stacks, each tote picking head accesses different stacks substantially simultaneously so that the picking head array accesses a group of stacks, and each different tote picking head enters, captures, and picks a tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking a tote from each stack of the group.

[0111] According to one aspect of the disclosed embodiments, a method is provided for stacking and separating totes with an automated product tote destacker tool. The method comprises the steps of: providing a frame for an automated product tote destacker tool, the frame having a coupling portion configured to fit the automated product tote destacker tool to a robot end so that the automated product tote destacker tool provides an end effector to the robot; and providing a picking head array of tote picking heads movably connected to and supported from the frame, wherein the picking head array is configured to simultaneously hold the tote array to the robot, with each different tote in the tote array being held by a corresponding tote picking head different from each other tote picking head that holds each other different tote in the tote array, and each tote picking head is to pick the tote A process comprising: a process having a tote grip that engages with a tote corresponding to a head; a process providing a drive section connected to a frame, the drive section being operably coupled to each tote picking head so as to move a tote picking head as a unit relative to the frame in accordance with the level of the corresponding tote; and a process for automatically and repeatedly picking totes from a stack of totes, wherein, with respect to each tote picking from the stack of totes, the tote picking head is weigh-controlled so as to automatically and repeatedly pick only the corresponding totes from the stack, throughout substantially the entire stack separation picking by an automated product tote destacker tool that separates the stack of totes from the top tote to the bottom tote of the stack.

[0112] According to one aspect of the disclosed embodiment, the method further includes the step of, by a weighing configuration of the picking head, when the tote picking head begins to tot-pick more than one tote from a stack of totes, the tote being automatically released from the tote grip of the tote picking head, thereby ensuring that each tote picking head that brings to tot-pick only the corresponding tote grasps the stack and separates the stacks.

[0113] According to one aspect of the disclosed embodiment, the tote grip is an active grip positioned to capture and grasp a corresponding tote on a tote picking head, and the active grip is metered and controlled so that the tote and grip separate when the tote picking head begins to tote picking one or more totes.

[0114] According to one aspect of the disclosed embodiment, the tote grips are distributed to form a plurality of grip contacts with respect to each tote picking head, which are configured to engage with the corresponding tote gripped by the tote picking head.

[0115] According to one aspect of the disclosed embodiment, each grip contact of the tote grip is arranged to elastically conform and seat on the inner bottom surface of the tote, and the tote picking head accesses the tote through the opening of the tote.

[0116] According to one aspect of the disclosed embodiment, each grip contact actively generates an upward gripping force on the tote when in operation, with the grip contact seated on the inner bottom surface of the gripped tote.

[0117] According to one aspect of the disclosed embodiment, the tote grip is configured to grip the corresponding tote on the tote picking head by an upward force, thereby causing tote picking and lifting the corresponding tote free from the stack, when at least one of the plurality of grip contacts of the tote picking head is not operational.

[0118] According to one aspect of the disclosed embodiment, the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

[0119] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding tote in the stack.

[0120] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding totes in the stack.

[0121] According to one aspect of the disclosed embodiment, each tote picking head of the picking head array has a corresponding one of at least one distance sensor positioned such that the position of the picking head array is determined relative to a group of stacks, each tote picking head accesses different stacks substantially simultaneously so that the picking head array accesses a group of stacks, and each different tote picking head enters, captures, and picks a tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking a tote from each stack of the group.

[0122] According to one aspect of the disclosed embodiment, a method is provided for stacking and separating totes with an automated product tote destacker tool. The method comprises the steps of: providing a frame for an automated product tote destacker tool, the frame having a coupling portion configured to fit the automated product tote destacker tool to a robot end so that the automated product tote destacker tool provides an end effector to the robot; and providing a picking head array of tote picking heads movably connected to and supported from the frame, the picking head array being configured to simultaneously hold the tote array to the robot, with each different tote in the tote array being held by a corresponding tote picking head different from each other tote picking head that holds each other different tote in the tote array. The process includes: a head having a tote grip that engages with a tote corresponding to a tote picking head, and each tote picking head being movably connected to a frame so that the tote picking head moves as a unit relative to the robot in accordance with the level of the corresponding tote; and a process in which each separate tote picking head brings forth tote picking from a stack of totes by weighing control, each tote picking head being brought forth substantially simultaneously by the picking head array and substantially simultaneously stacking and separating the stack of totes by an automated product tote destacker tool, wherein each separate tote picking head is weighing control so that it separately grasps only the corresponding tote from its respective tote picking head.

[0123] According to one aspect of the disclosed embodiments, the method further includes the step of providing a drive section supported from a frame and operably connected to each tote-picking head, thereby acting the tote-picking heads in at least one direction relative to a robot.

[0124] According to one aspect of the disclosed embodiment, with respect to each tote picking from a stack of totes, the tote picking head is weigh-controlled so that, throughout substantially the entire stack separation picking by an automated product tote destacker tool that separates the stack of totes from the top tote to the bottom tote of the stack, the picking head automatically and repeatedly picks only the corresponding tote from the stack.

[0125] According to one aspect of the disclosed embodiment, the method further includes the step that, by a weighing configuration of the picking head, when the tote picking head begins to tot-pick more than one tote from a stack of totes, the tote is automatically released from the tote grip of the tote picking head, so that each tote picking head that brings to tot-pick grasps only the corresponding tote and separates the stacks.

[0126] According to one aspect of the disclosed embodiment, the tote grip is an active grip positioned to capture and grasp a corresponding tote on a tote picking head, and the active grip is metered and controlled so that the tote and grip separate when the tote picking head begins to tote picking one or more totes.

[0127] According to one aspect of the disclosed embodiment, the tote grips are distributed to form a plurality of grip contacts with respect to each tote picking head, which are configured to engage with the corresponding tote gripped by the tote picking head.

[0128] According to one aspect of the disclosed embodiment, each grip contact of the tote grip is arranged to elastically conform and seat on the inner bottom surface of the tote, and the tote picking head accesses the tote through the opening of the tote.

[0129] According to one aspect of the disclosed embodiment, each grip contact actively generates an upward gripping force on the tote when in operation, with the grip contact seated on the inner bottom surface of the gripped tote.

[0130] According to one aspect of the disclosed embodiment, the tote grip is configured to grip the corresponding tote on the tote picking head by an upward force, thereby causing tote picking and lifting the corresponding tote free from the stack, when at least one of the plurality of grip contacts of the tote picking head is not operational.

[0131] According to one aspect of the disclosed embodiment, the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

[0132] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine the bottom of a corresponding tote in the stack.

[0133] According to one aspect of the disclosed embodiment, the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding totes in the stack.

[0134] According to one aspect of the disclosed embodiment, each tote picking head of the picking head array has a corresponding one of at least one distance sensor positioned such that the position of the picking head array is determined relative to a group of stacks, each tote picking head accesses different stacks substantially simultaneously so that the picking head array accesses a group of stacks, and each different tote picking head enters, captures, and picks a tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking a tote from each stack of the group.

[0135] 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. An automated product tote destacker tool, wherein the automated product tote destacker tool is The automatic product tote destacker tool has a frame with a connecting portion configured to fit the automatic product tote destacker tool to the end of a robot so as to provide an end effector to the robot, A picking head array of tote picking heads movably connected to and supported from the frame, wherein each different tote of the tote array is held by a corresponding tote picking head different from each other tote picking head that holds each other different tote of the tote array, and the picking head array is configured to simultaneously hold the tote array on the robot, with each tote picking head having a tote grip that engages with the tote corresponding to the tote picking head, A drive section connected to the frame, the drive section being operably connected to each tote picking head so as to move the tote picking head as a unit relative to the frame in accordance with the level of the corresponding tote, An automated product tote destacker tool, wherein, with respect to each tote picking from a stack of totes, the tote picking head is weigh-controlled so that, throughout substantially the entire stack separation picking by the automated product tote destacker tool that separates the stack of totes from the top tote to the bottom tote of the stack, the tote picking head automatically and repeatedly picks only the corresponding tote from the stack.

2. The automatic product tote destacker tool according to claim 1, wherein the weighing configuration of the picking head causes the tote picking head to automatically detach the tote from the tote grip when the tote picking head begins to tote picking more than one tote from the tote stack, thereby ensuring that each tote picking head that is tote picking grasps only the corresponding tote and separates the stack.

3. The automated product tote destacker tool according to claim 1, wherein the tote grip is an active grip positioned to capture and grasp the corresponding tote on the tote picking head, and the active grip is weigh-controlled such that the tote and grip separate when the tote picking head begins to tote-pick more than one tote.

4. The automated product tote destacker tool according to claim 1, wherein the tote grips are distributed to form a plurality of grip contacts configured to engage with the corresponding tote gripped by the tote picking head with respect to each tote picking head.

5. The automatic product tote destacker tool according to claim 4, wherein each grip contact of the tote grip is elastically conforming and positioned to sit on the inner bottom surface of the tote, and the tote picking head accesses the tote through an opening in the tote.

6. The automatic product tote destacker tool according to claim 5, wherein each grip contact actively generates an upward gripping force on the tote while the grip contact is seated on the inner bottom surface of the gripped tote during operation.

7. The automated product tote destacker tool according to claim 6, wherein the tote grip is configured to grip the corresponding tote on the tote picking head by the upward gripping force, thereby causing the tote picking and lifting the corresponding tote freely from the stack, when at least one of the plurality of grip contacts of the tote picking head is not operating.

8. The automated product tote destacker tool according to claim 1, wherein the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

9. The automated product tote destacker tool according to claim 1, wherein the picking head array has at least one distance sensor arranged to determine the bottom of the corresponding tote in the stack.

10. The automated product tote destacker tool according to claim 1, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding tote in the stack.

11. An automated product tote destacker tool according to claim 10, wherein each tote picking head of the picking head array has a corresponding one of the at least one distance sensors positioned such that the position of the picking head array is determined relative to the group of stacks, each tote picking head accesses different stacks substantially simultaneously so that the picking head array accesses the group of stacks, and each different tote picking head enters, captures, and tot-picks the tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking totes from each stack of the group.

12. An automated product tote destacker tool, wherein the automated product tote destacker tool is The automatic product tote destacker tool has a frame with a connecting portion configured to fit the automatic product tote destacker tool to the end of a robot so as to provide an end effector to the robot, A picking head array of tote picking heads movably connected to and supported from the frame, wherein the picking head array is configured to simultaneously hold the tote array to the robot, with each different tote of the tote array held by a corresponding tote picking head different from each other tote picking head that holds each other different tote of the tote array, and each tote picking head has a tote grip that engages with the tote corresponding to the tote picking head, Each tote picking head is movably connected to the frame so that the tote picking head moves as a unit relative to the robot in accordance with the level of the corresponding tote. An automated product tote destacker tool, wherein each separate picking head, which brings each tote picking from a stack of totes, is brought by the picking head array substantially simultaneously, and with respect to each tote picking, which substantially simultaneously separates the stack of totes by the automated product tote destacker tool, the tote picking heads are weigh-controlled so that each tote picking head separately grasps only the corresponding tote.

13. The automated product tote destacker tool according to claim 12, further comprising a drive section supported from the frame and operably connected to each tote picking head, thereby acting the tote picking head in at least one direction relative to the robot.

14. The automatic product tote destacker tool according to claim 12, wherein, with respect to each tote picking from a stack of totes, the tote picking head is weighed and controlled so that, throughout substantially the entire stack separation picking by the automatic product tote destacker tool that separates the stack of totes from the top tote to the bottom tote of the stack, the tote picking head automatically and repeatedly picks only the corresponding tote from the stack.

15. The automatic product tote destacker tool according to claim 12, wherein the weighing configuration of the picking head causes the tote picking head to automatically detach the tote from the tote grip when the tote picking head begins to tote picking more than one tote from the tote stack, so that each tote picking head that is tote picking grasps only the corresponding tote and separates the stack.

16. The automated product tote destacker tool according to claim 12, wherein the tote grip is an active grip positioned to capture and grasp the corresponding tote on the tote picking head, and the active grip is weigh-controlled such that the grip separates from the tote when the tote picking head begins to tote-pick more than one tote.

17. The automated product tote destacker tool according to claim 12, wherein the tote grips are distributed to form a plurality of grip contacts configured to engage with the corresponding tote gripped by the tote picking head with respect to each tote picking head.

18. The automatic product tote destacker tool according to claim 17, wherein each grip contact of the tote grip is elastically conforming and positioned to sit on the inner bottom surface of the tote, and the tote picking head accesses the tote through an opening in the tote.

19. The automatic product tote destacker tool according to claim 18, wherein each grip contact actively generates an upward gripping force on the tote while the grip contact is seated on the inner bottom surface of the gripped tote during operation.

20. The automated product tote destacker tool according to claim 19, wherein the tote grip is configured to grip the corresponding tote on the tote picking head by the upward gripping force, thereby causing the tote picking and lifting the corresponding tote freely from the stack, when at least one of the plurality of grip contacts of the tote picking head is not operating.

21. The automated product tote destacker tool according to claim 12, wherein the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

22. The automated product tote destacker tool according to claim 12, wherein the picking head array has at least one distance sensor arranged to determine the bottom of the corresponding tote in the stack.

23. The automated product tote destacker tool according to claim 12, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding tote in the stack.

24. An automated product tote destacker tool according to claim 23, wherein each tote picking head of the picking head array has a corresponding one of the at least one distance sensors positioned such that the position of the picking head array is determined relative to the group of stacks, each tote picking head accesses different stacks substantially simultaneously so that the picking head array accesses the group of stacks, and each different tote picking head enters, captures, and tot-picks the tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking totes from each stack of the group.

25. A method for stacking and separating totes using an automated product tote destacker tool, wherein the method is A step of providing the frame for the automated product tote destacker tool, wherein the frame has a connecting portion configured to fit the automated product tote destacker tool to the end of a robot so that the automated product tote destacker tool provides an end effector to the robot, A step of providing a picking head array of tote picking heads movably connected to and supported from the frame, wherein the picking head array is configured to simultaneously hold the tote array to the robot, with each different tote of the tote array held by a corresponding tote picking head different from each other tote picking head that holds each other different tote of the tote array, and each tote picking head has a tote grip that engages with the tote corresponding to the tote picking head, A step of providing a drive section connected to the frame, wherein the drive section is operably connected to each tote picking head so as to move the tote picking head as a unit relative to the frame in accordance with the level of the corresponding tote; A method for automatically and repeatedly picking totes from a stack of totes, wherein, with respect to each tote picking from the stack of totes, the tote picking head is weigh-controlled to automatically and repeatedly pick only the corresponding totes from the stack, throughout substantially the entire stack separation picking by the automated product tote destacker tool which separates the stack of totes from the top tote to the bottom tote of the stack.

26. The method according to claim 25, further comprising the step that, due to the weighing configuration of the picking head, when the tote picking head begins to tot-pick more than one tote from the stack of totes, the tote picking head automatically detaches the tote from the tote grip, thereby ensuring that each tote picking head that brings up the tote picking grasps only the corresponding tote and separates the stack.

27. The method according to claim 25, wherein the tote grip is an active grip positioned to capture and grasp the corresponding tote on the tote picking head, and the active grip is meter-controlled such that the grip separates from the tote when the tote picking head begins to tote-pick more than one tote.

28. The method according to claim 25, wherein the tote grips are distributed to form a plurality of grip contacts with respect to each tote picking head, configured to engage with the corresponding tote gripped by the tote picking head.

29. The method according to claim 28, wherein each grip contact of the tote grip is arranged to elastically conform and sit on the inner bottom surface of the tote, and the tote picking head accesses the tote through an opening in the tote.

30. The method according to claim 29, wherein each grip contact actively generates an upward gripping force on the tote while the grip contact is seated on the inner bottom surface of the gripped tote during operation.

31. The method according to claim 30, wherein the tote grip is configured to grip the corresponding tote on the tote picking head by the upward gripping force, thereby causing the tote picking and lifting the corresponding tote freely from the stack, when at least one of the plurality of grip contacts of the tote picking head is not operating.

32. The method according to claim 25, wherein the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

33. The method according to claim 25, wherein the picking head array has at least one distance sensor arranged to determine the bottom of the corresponding tote in the stack.

34. The method according to claim 25, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding tote in the stack.

35. The method according to claim 34, wherein each tote picking head of the picking head array has a corresponding one of the at least one distance sensors arranged such that the position of the picking head array is determined relative to the group of stacks, each tote picking head accesses different stacks substantially simultaneously so that the picking head array accesses the group of stacks, and each different tote picking head enters, captures, and tote picks the tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking totes from each stack of the group.

36. A method for stacking and separating totes using an automated product tote destacker tool, wherein the method is A step of providing the frame for the automated product tote destacker tool, wherein the frame has a connecting portion configured to fit the automated product tote destacker tool to the end of a robot so that the automated product tote destacker tool provides an end effector to the robot, A step of providing a picking head array of tote picking heads movably connected to and supported from the frame, wherein the picking head array is configured to simultaneously hold the tote array to the robot, with each different tote of the tote array held by a corresponding tote picking head different from each other tote picking head that holds each other different tote of the tote array, and each tote picking head has a tote grip that engages with the tote corresponding to the tote picking head, and each tote picking head is movably connected to the frame such that the tote picking head moves as a unit relative to the robot in accordance with the level of the corresponding tote; A method comprising the steps of: each separate tote picking head being weigh-controlled to bring about tote picking from a stack of totes, wherein with respect to each tote picking which is brought about substantially simultaneously by the picking head array and which is stacked and separated substantially simultaneously by the automatic product tote destacker tool, each separate tote picking head is weigh-controlled to separately grasp only the corresponding tote from its respective tote picking head.

37. The method according to claim 36, further comprising the step of providing a drive section supported from the frame and operably connected to each tote-picking head, thereby acting the tote-picking heads in at least one direction relative to the robot.

38. The method according to claim 36, wherein, with respect to each tote picking from a stack of totes, the tote picking head is weigh-controlled to automatically and repeatedly pick only the corresponding totes from the stack, throughout substantially the entire stack separation picking by the automatic product tote destacker tool which separates the stack of totes from the top tote to the bottom tote of the stack.

39. The method according to claim 36, further comprising the step that, due to the weighing configuration of the picking head, when the tote picking head begins to tot-pick more than one tote from the stack of totes, the tote picking head automatically detaches the tote from the tote grip, thereby ensuring that each tote picking head that brings up the tote picking grasps only the corresponding tote and separates the stack.

40. The method according to claim 36, wherein the tote grip is an active grip positioned to capture and grasp the corresponding tote on the tote picking head, and the active grip is meter-controlled such that the grip separates from the tote when the tote picking head begins to tote-pick more than one tote.

41. The method according to claim 36, wherein the tote grips are distributed to form a plurality of grip contacts with respect to each tote picking head, configured to engage with the corresponding tote gripped by the tote picking head.

42. The method according to claim 41, wherein each grip contact of the tote grip is arranged to elastically conform and sit on the inner bottom surface of the tote, and the tote picking head accesses the tote through an opening in the tote.

43. The method according to claim 42, wherein each grip contact actively generates an upward gripping force on the tote while the grip contact is seated on the inner bottom surface of the gripped tote during operation.

44. The method according to claim 43, wherein the tote grip is configured to grip the corresponding tote on the tote picking head by the upward gripping force, thereby causing the tote picking and lifting the corresponding tote freely from the stack, when at least one of the plurality of grip contacts of the tote picking head is not operating.

45. The method according to claim 36, wherein the tote grip is a vacuum grip generated by a venturi that provides metered-controlled suction to grip the corresponding tote.

46. The method according to claim 36, wherein the picking head array has at least one distance sensor arranged to determine the bottom of the corresponding tote in the stack.

47. The method according to claim 36, wherein the picking head array has at least one distance sensor arranged to determine one or more of the sides, edges, and openings of the corresponding tote in the stack.

48. The method according to claim 47, wherein each tote picking head of the picking head array has a corresponding one of the at least one distance sensors arranged such that the position of the picking head array is determined relative to the group of stacks, each tote picking head accesses different stacks substantially simultaneously so that the picking head array accesses the group of stacks, and each different tote picking head enters, captures, and tote picks the tote corresponding to the tote picking head substantially simultaneously with each of the other different tote picking heads of the picking head array picking totes from each stack of the group.

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