Automated Load Handling System

Abstract

An automated load handling system (50) comprising: A) a first automated storage and retrieval system (52) and a second automated storage and retrieval system (54); and B) at least one port column (58), wherein A) each of the first and second automated storage and retrieval systems (52, 54) comprises: i) a grid framework structure (1); and ii) a plurality of robotic load handling devices (31), wherein i) the grid framework structure (1) comprises: a) a track system comprising a plurality of grid cells arranged in a grid pattern, each grid cell defining a grid opening (15); and b) a plurality of storage columns each arranged to store a respective stack of storage containers for storing one or more items, the stacks of storage containers being positioned below the track system such that each stack of storage containers occupies a single grid space or grid cell; ii) the robotic load handling device (31) is operable on the track system to lift and move the one or more storage containers from the stacks; and B C) at least one transfer system (56) configured to transfer one or more storage containers or one or more items from the storage containers from the at least one port column (58) of the first automated storage and retrieval system (52) to the at least one port column of the second automated storage and retrieval system (54), wherein the grid opening (15) of the track system of the first automated storage and retrieval system is configured such that the grid framework structure of the first automated storage and retrieval system is configured to store storage containers that are sized differently than the storage containers stored in the grid framework structure of the second automated storage and retrieval system;an automated load handling system, characterized in that the grid openings (15) of the track system of the second automated storage and retrieval system (54) are of a different size than the grid openings (15) of the track system;

Description

[Technical field]

[0001] The present invention relates to an automated load handling system that includes an automated storage and retrieval system for handling storage containers or bulk containers. [Background technology]

[0002] Some commercial and industrial activities require systems that allow the storage and retrieval of many different products. Generally, a warehouse for the storage and retrieval of products or items comprises a series of racks, which are accessible by a transport device with a lifting device, such as a forklift, that is movable in the aisles between the racks. The products or items are typically stored on pallets or other storage containers and placed at different heights on the racks. A transport device, either manually driven or automatic, travels up and down the aisles between the racks, and a lifting device is used to remove the pallet or the items on the pallet that store a particular product from the rack. However, the storage and retrieval of products is very laborious and time-consuming.

[0003] PCT Publication WO 2015 / 185628A (Ocado) describes a known automated storage and retrieval system in which a stack of bins or containers is arranged within a grid framework structure. The bins or containers, known as storage bins or containers or storage containers, are stacked one on top of the other to form a stack. The stacks are arranged within the grid framework structure in a warehouse or distribution center. The bins or containers are accessed by remotely operable robotic load handling devices (otherwise known as bots) on trucks located on top of the grid framework structure. While the automated storage and retrieval system taught in WO 2015 / 185628A (Ocado) provides a very dense system for storage of items, the automated storage and retrieval system is not capable of matching bins or containers based on specific attributes of the contents of the bins or containers being stored.

[0004] For example, where the industrial activity is a baggage handling system at an airport, the verification of large bins or containers is required. Airport terminals around the world typically use some form of system to check in passenger baggage, load it into the cargo hold of an airplane prior to the departure of a flight, and return the passenger baggage at the end of the flight. The equipment required to provide this service, especially at large international airports, can be quite expensive. Known baggage transport systems used within airports can include a check-in system on departures and a collection system on arrivals.

[0005] An example of baggage flow during check-in and collection at an airport may include the following: Passengers deposit their baggage at a check-in desk at the terminal. The passenger's baggage is then placed on a conveyor that carries the baggage to a chute, which guides the baggage to a build cell, which may be located on a lower level of the building. Large international terminals may use 200 or more build cells below the check-in area.

[0006] Build cells of the type used in such conventional baggage systems typically include a conveyor for conveying baggage that exits the chute and away from the chute exit.

[0007] One or more manual handlers are assigned to each build cell to remove baggage from the conveyor and place it on a loading station adjacent to the conveyor. Each build cell is designated to collect baggage for a specific flight to prevent baggage from being sent to the wrong destination. A tag and dolly transport system then pulls up alongside the loading station and the baggage is manually loaded into unit load devices (ULDs), also known as flight cans or baggage carts.

[0008] ULDs serve to allow for the consolidation or collation of large quantities of cargo into one unit. This reduces ground crew time and effort in loading the aircraft since there are fewer individual units to handle. Once the ULDs are loaded onto the tugs and dollies, they are transported to the aircraft and, depending on the particular aircraft, airline, and any applicable rules or regulations, the baggage is either stored on board the aircraft in the ULD or manually unloaded into the aircraft.

[0009] The baggage handling system described above suffers from many problems. The conveyors must be located at ground level to move the baggage to the loading station and for pick-up by the tugs and dollies. If multiple build cells are used, a large surface area is taken up. Furthermore, the check-in time for a flight generally takes up to about three hours. If the baggage seated on a conveyor cannot be loaded onto a ULD before all passengers have checked in, that particular conveyor cannot be utilized to store baggage for other flights during this time.

[0010] Transfer of baggage from the base of the chute onto a baggage cart or ULD has been accomplished by manual lifting and positioning, but concerns have been raised about injuries that may result from such manual effort.

[0011] Therefore, there is a need for an automated load handling system that does not suffer from the problems discussed above. Summary of the Invention

[0012] The present invention has alleviated the above problems by providing an automated load handling system (also referred to as load handling system or automated handling system) based on the high storage capacity of the storage and retrieval system described in publication WO 2015 / 185628A (Ocado). The three-dimensional grid framework structure described in publication WO 2015 / 185628A (Ocado) has the ability to store items or storage containers at a high density on a given footprint of the grid framework structure compared to other storage and retrieval systems known in the art. To overcome the problems of the storage and retrieval system described in WO 2015 / 185628A (Ocado) having the ability to collate and / or sort one or more stored items, the present invention provides an automated load handling system comprising A) first and second automated storage and retrieval systems and B) at least one port column, A) a first and a second automated storage and retrieval system, each of the first and second automated storage and retrieval systems comprising: i) a grid framework structure; and ii) a plurality of robotic load handling devices; i) a grid framework structure, a) a track system comprising a first set of parallel tracks and a second set of parallel tracks extending transversely to the first set in a substantially horizontal plane, the track system being arranged in a grid pattern comprising a plurality of grid cells, each grid cell defining a grid opening defined by a pair of adjacent tracks of the first set of parallel tracks and a pair of adjacent tracks of the second set of parallel tracks; b) a plurality of storage columns, each arranged to store a respective stack of storage containers for storing one or more items, the stacks of storage containers positioned below the track system such that each stack of storage containers occupies a single grid space or grid cell; Equipped with ii) the robotic load handling device is operable on the track system to lift and move one or more storage containers from the stack; B) a port column extends downwardly from a grid opening in the track system of each of the first and second automated storage and retrieval systems, through which a respective robotic load handling device operable on the track system can drop off and pick up one or more storage containers; In an automated load handling system, the automated load handling system C) at least one transfer system configured to transfer one or more storage containers or one or more items from the storage containers from at least one port column of the first automated storage and retrieval system to at least one port column of the second automated storage and retrieval system; An automated load handling system is provided, characterized in that the grid openings of the track system of the first automated storage and retrieval system are differently sized than the grid openings of the track system of the second automated storage and retrieval system such that the grid framework structure of the first automated storage and retrieval system is configured to store storage containers that are sized differently than storage containers stored within the grid framework structure of the second automated storage and retrieval system.

[0013] By providing the first and second automated storage and retrieval systems, each of which comprises a grid framework structure and a plurality of robotic load handling devices operable on a track system for lifting and moving one or more storage containers from the stack, the load handling device according to the present invention can leverage the high storage density and automation of its respective grid framework structure for storage and retrieval of the storage containers. To enable the automated load handling system of the present invention to sort and / or collate the one or more storage containers or one or more items from the storage containers, the automated load handling system further comprises at least one transfer system configured to transfer the one or more storage containers or one or more items from the storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system. A relationship between the grid framework structure of the first automated storage and retrieval system and the grid framework structure of the second automated storage and retrieval system provided by the at least one transfer system allows the storage containers or items from the storage containers to be collated or aggregated or sorted in one or more containers before being removed from the first storage and retrieval system and stored in the second storage and retrieval system. To collate the one or more storage containers or items from the storage containers for storage in the second storage and retrieval system, the grid openings of the track system of the first automated storage and retrieval system are sized differently from the grid openings of the track system of the second automated storage and retrieval system such that the grid framework structure of the first automated storage and retrieval system is configured to store differently sized storage containers than storage containers stored in the grid framework structure of the second automated storage and retrieval system.This creates a mismatch of the grid framework structures, meaning that each mismatched grid framework structure allows differently sized storage containers to be stored in its respective mismatched grid framework structure, and at least one transfer system is required to transfer one or more storage containers or one or more items from the storage containers between the mismatched grid framework structures. For purposes of the present invention, the size of the grid opening represents the length of the diagonal line that spans the maximum grid opening of the track system as the robotic load handling device moves across the track system. Preferably, the grid opening of the track system of the first automated storage and retrieval system is smaller than the grid opening of the track system of the second automated storage and retrieval system, such that the grid framework structure of the first automated storage and retrieval system is configured to store smaller storage containers than the storage containers stored in the grid framework structure of the second automated storage and retrieval system.

[0014] Each respective grid framework structure of the first and second storage and retrieval systems comprises a track system comprising a first set of parallel tracks and a second set of parallel tracks extending transversely to the first set of parallel tracks in the sense that the first and second sets of parallel tracks are arranged in a grid pattern located in a horizontal plane comprising a plurality of grid spaces or grid cells having grid openings, such that the first set of parallel tracks guides the robotic load handling device in an X direction and the second set of parallel tracks guides the robotic load handling device in a Y direction.

[0015] The storage containers are stored in stacks within one or more storage columns of the grid framework structures of each of the first and second storage and retrieval systems, where each stack of storage containers is arranged to occupy a single grid space or grid cell, such that openings in the grid cells or grid spaces correspond to storage columns over which a load handling device operable on a track system can move laterally over each of the storage columns to retrieve a storage container in the stack.

[0016] Each of the plurality of robotic load handling devices comprises a car body and a wheel assembly arranged to travel in the X and Y directions on a track system of a grid framework structure above the stack. The wheel assembly comprises two sets of wheels extending on the track system. Each of the two sets of wheels is driven to enable movement of the vehicle in the X and Y directions, respectively, along the tracks. A first set of wheels, consisting of a pair of wheels at the front of the vehicle and a pair of wheels at the rear of the vehicle, is arranged to engage two adjacent tracks of the first set of tracks. Similarly, a second set of wheels, consisting of a pair of wheels on each side of the vehicle, is arranged to engage two adjacent tracks of the second set of tracks. When the first set of wheels is engaged with the first set of tracks and the second set of wheels is lifted off the tracks or rails, the wheels can be driven by a drive mechanism housed within the car body to move the robotic load handling device in the X direction. To move the load handling device in the Y direction, a first set of wheels is lifted off the tracks or rails and a second set of wheels is lowered into engagement with the second set of tracks or rails. A drive mechanism may then be used to drive the second set of wheels to accomplish movement in the Y direction. One or both sets of wheels can be moved vertically to lift each set of wheels off their respective rails, thereby allowing the vehicle to move in a desired direction on the track system.

[0017] Additionally, each of the plurality of robotic load handling devices comprises a container receiving space for receiving and accommodating the storage container as it is transported across the top of the grid. The container receiving space may comprise a cavity or recess disposed within the vehicle body, for example, as described in WO 2015 / 019055 (Ocado Innovation Limited). Alternatively, the vehicle body of the load handling device may comprise a cantilever as taught in WO 2019 / 238702 (Autostore Technology AS), in which case the container receiving space is located below the cantilever of the robotic load handling device.

[0018] Each respective grid framework structure of the first and second storage and retrieval systems has at least one grid column that is not used as a storage column for storing storage containers in a stack. This at least one grid column is instead used by a robotic load handling device to drop off and / or pick up storage containers so that the storage containers can be transferred to at least one transport system, where the contents of the storage containers can be accessed from outside the grid framework structure of the first storage and retrieval system and transferred via the at least one transport system to the grid framework structure of the second storage and retrieval system. For the purposes of the present invention, a grid opening of the at least one grid column is referred to as a "port" and the at least one grid column in which the port is located is referred to as "at least one port column". The at least one port column extends downwardly from a grid opening of each of the track systems of the first and second automated storage and retrieval systems. Through the respective grid openings, the respective robotic load handling devices operable on the track systems can drop off and pick up one or more storage containers. Optionally, the at least one port column comprises two port columns, a first port column dedicated as a drop-off port column and defined as an exit port column at which a robotic load handling device can drop off storage containers to the at least one transport system, and a second port column dedicated as a pickup port column and defined as an entrance port column at which a robotic load handling device can pick up storage containers delivered to the port column from the at least one transport system.

[0019] Optionally, the at least one transfer system comprises a conveyor system comprising at least one conveyor unit extending from a port column of the grid framework structure of the first automated storage and retrieval system to a port column of the grid framework structure of the second automated storage and retrieval system for transporting one or more storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system. In this example, the at least one conveyor unit extends between the port columns from the first and second storage and retrieval systems such that the storage containers may be directly transferred from the first storage and retrieval system to the second storage and retrieval system, where the storage containers may be matched based on attributes of the contents of the storage containers, e.g. user details, flight number in case of an airport baggage handling system, etc.

[0020] To enable the transfer of contents of the storage containers from the first storage and retrieval system to storage containers entering the second storage and retrieval system, optionally the at least one transfer system comprises a pick station or picking station for receiving storage containers dropped off from a port column of the grid framework structure of the first automated storage and retrieval system. The pick station enables the contents of the storage containers dropped off to the at least one port column to be accessed for picking from outside the grid framework structure. At the pick station, one or more items can be picked from the storage containers dropped off to the at least one port column of the grid framework structure of the first storage and retrieval system. The one or more picked items can then be collated and / or sorted for transfer to a differently sized storage container for later storage via its respective at least one port column within the grid framework structure of the second storage and retrieval system. Although certain embodiments describe the picking station being arranged to transfer, via at least one transport system, the contents of a storage container dropped off to at least one port column of a first storage and retrieval system to a storage container dropped off to at least one port column of a second storage and retrieval system, the invention is not limited to the transfer of the contents of a storage container and may include transferring the storage container itself, via at least one transport system, from the pick station to a differently sized storage container for storage within the grid framework structure of the second storage and retrieval system. Alternatively, one or more items may be placed in a separate shipping storage container, and the shipping storage container may be placed inside the storage container for storage within the grid framework structure of the second storage and retrieval system.The shipping storage container provides the convenience of keeping one or more items together within a storage container and easily transferring the contents of the storage container to a differently sized storage container for storage within the grid framework structure of a second storage and retrieval system.

[0021] Optionally, at least one port column of the grid structure of the second automated storage and retrieval system comprises an entry port column for receiving one or more storage containers transferred from the at least one transfer system and an exit port column for dropping off the one or more storage containers to the at least one transfer system. To transfer the contents of the storage containers from the pick station to the storage containers for subsequent storage within the grid structure of the second storage and retrieval system, the at least one transfer system comprises a buffer zone for holding one or more storage containers dropped off from the exit port column of the first and / or second automated storage and retrieval system. The differently sized storage containers are held in the buffer zone such that one or more items in the one or more storage containers at the pick station can be transferred to the differently sized storage container in the buffer zone for subsequent transfer to the grid framework structure of the second storage and retrieval system. Alternatively, one or more storage containers can be transferred from the at least one port column of the first automated storage and retrieval system to a storage container held in the buffer zone of the second automated storage and retrieval system. Optionally, the buffer zone comprises a decant station configured to receive one or more items picked from the pick station.

[0022] Optionally, the at least one transfer system comprises at least one conveyor system comprising at least one conveyor unit extending from an exit port column of the grid framework structure of the first or second automated storage and retrieval system to an entrance port column of the grid framework structure of the first or second automated storage and retrieval system for transporting one or more storage containers into and out of a respective grid framework structure of the automated storage and retrieval system.

[0023] Optionally, the at least one transfer system comprises a conveyor system comprising at least one conveyor unit extending from at least one port column of the grid framework structure of the first automated storage and retrieval system to at least one port column of the grid framework structure of the second automated storage and retrieval system for transporting one or more storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system.

[0024] Optionally, the at least one transfer system comprises at least one conveyor system comprising a first conveyor system arranged to transport one or more storage containers to and from a grid framework structure of the first automated storage and retrieval system and a second conveyor system arranged to transport one or more storage containers to and from a grid framework structure of the second automated storage and retrieval system. The first conveyor system is arranged to transport the one or more storage containers from an exit port column to an entry port column via a transfer conveyor unit of the grid framework structure of the first automated storage and retrieval system. Similarly, the second conveyor system is arranged to transport the one or more storage containers from an exit port column to an entry port column via a transfer conveyor unit of the grid framework structure of the second automated storage and retrieval system.

[0025] To transport one or more storage containers into and out of the grid framework structure of the first automated storage and retrieval system or the second automated storage and retrieval system, optionally the at least one conveyor system comprises an entrance conveyor unit, an exit conveyor unit, and a transfer conveyor unit, the exit conveyor unit arranged to transport the storage containers in a first direction from the exit port column to the transfer conveyor unit, and the entrance conveyor unit arranged to transport the storage containers in a second direction from the transfer conveyor unit to the entrance port column.

[0026] At least one conveyor system of the at least one transfer system transports the storage container from the exit port to the entry port through a buffer zone, where the storage container is held in the buffer zone to receive the storage container or one or more items from the storage container delivered from the first storage and retrieval system. Optionally, the transfer conveyor unit is arranged to transport the storage container from the exit conveyor unit to the entry conveyor unit. Optionally, the exit conveyor unit and the entry conveyor unit are arranged such that a first direction of the exit conveyor unit is opposite and parallel to a second direction of the entry conveyor unit, where a third direction of the transfer conveyor unit is substantially perpendicular to both the first direction of the exit conveyor unit and the second direction of the entry conveyor unit. Thus, the storage container that exits the grid framework structure of the second storage and retrieval system via the exit port travels in a substantially "U" shaped path to the entry port of the grid structure.

[0027] The transfer of one or more items from the pick station to a storage container in the buffer zone of the second automated storage and retrieval system may be performed by manual operation or by automatic operation. Optionally, the pick station comprises a robotic arm for transferring one or more items from the one or more storage containers of the first automated storage and retrieval system dropped off at the pick station to one or more storage containers in the buffer zone, preferably in the transfer conveyor unit of the second automated storage and retrieval system. To assist in picking one or more items from the pick station, preferably the pick station comprises a tilting mechanism for tilting the storage container and a slide adjacent to the tilting mechanism for capturing one or more items exiting the tilting mechanism.

[0028] Optionally, the storage container of the first automated storage and retrieval system comprises shallow trays mounted on spacing means so as to be vertically spaced from one another within a stack within the grid framework structure of the first automated storage and retrieval system, each of the shallow trays comprising a bottom wall and an upwardly extending rim comprising one or more cut-outs through which one or more items within the shallow tray may be accessed when the shallow tray is stored within a stack within the grid framework structure of the first automated storage and retrieval system.

[0029] Preferably, each load handling device of the plurality of load handling devices of the first and second automated storage and retrieval systems comprises a lifting mechanism comprising a gripping device configured to releasably engage with a storage container and a winch mechanism configured to lift the storage container above the track system. The lifting mechanism may be located inside the vehicle body and comprises a lifting frame, otherwise known as a gripping device, adapted to releasably fit with the storage container, a lifting tether wound on at least one spool, and a winch mechanism comprising a winch motor configured to lift the storage container from the stack above the track system. The gripping device may be lowered from the vehicle body such that its position allows it to attach a top or rim of the storage container. The gripping device comprises a gripping element configured to grip a rim of the storage container such that the storage container is lifted into a container receiving space of the robotic load handling device when the winch motor is powered.

[0030] To enable automatic, reliable routing of items received in the automated load handling system of the present invention, preferably the automated load handling system further comprises a control system comprising one or more processors and a memory storing instructions, which when executed by the one or more processors: a) receiving a request for storage of an item associated with at least a portion of a user or product; b) generating a unique identification comprising data associated with at least a portion of a user or a product; c) assigning unique identities to storage containers within the first automated storage and retrieval system; d) configured to store data associated with the unique identification in a database.

[0031] Data associated with the user includes, but is not limited to, the user's name, and / or place of residence, and / or other attributes associated with the user, such as place of work. Alternatively, the unique identification may comprise data associated with at least a portion of a product. Optionally, the automated load handling system of the present invention may form part of an assembly line, where one or more items retrieved from one or more storage containers from a first automated storage and retrieval system may be assembled together to form at least a portion of a product or an entire product before being transferred for storage within the grid framework structure of a second automated storage and retrieval system. Optionally, at least one transfer system comprises at least one assembly station for assembling one or more items from one or more storage containers from the first automated storage and retrieval system.

[0032] Preferably, the unique identification is assigned to the storage container in the first automated storage and retrieval system by correlating the grid location of the storage container in the grid framework structure of the first automated storage and retrieval system to the unique identification. One way to assign a unique identification associated with a user to a storage container in the first automated storage and retrieval system is by correlating the location of the storage container in the grid framework structure of the first automated storage and retrieval system to the unique identification. For purposes of the present invention, the track system guides the movement of the robotic load handling device in the X and Y directions in a horizontal plane, and the lifting mechanism is configured to move the gripping device in a third Z direction to access the storage containers in the stack. For purposes of the present application, Z=1 defines the top layer of the grid framework structure, i.e., the layer immediately below the track system, Z=2 is the second layer below the track system, Z=3 is the third layer below the track system, and so on. The positions of each of the storage containers held in the grid framework structures of the first and second storage and retrieval systems may be represented by a Cartesian coordinate system X, Y, Z. For example, a storage container may be said to be located at a grid location determined from a Cartesian coordinate system X,Y,Z.

[0033] Just as the storage containers within the grid framework structure of the first storage and retrieval system are assigned unique identities associated with respective users, the control system a) generating a unique identification comprising data associated with each storage container within a second automated storage and retrieval system; b) further configured to assign a unique identification of the storage container to a location of the storage container within the grid framework structure of the second automated storage and retrieval system.

[0034] In addition to generating a unique identification associated with the user and assigning the unique identification to a grid location (X, Y, Z) of the first automated storage and retrieval system, the control system further generates a unique identification comprising data associated with each storage container in the grid framework structure of the second automated storage and retrieval system and assigns the unique identification of the storage container to the grid location of the storage container in the grid framework structure of the second automated storage and retrieval system. In this manner, the control system can correctly identify an item or storage container from the grid framework structure of the first storage and retrieval system that should be transferred to the correct storage container in the grid framework structure of the second storage and retrieval system. Preferably, the control system is configured to aggregate or match multiple items from one or more storage containers in the first storage and retrieval system based on their respective unique identifications for transfer to a storage container in the grid framework structure of the second automated storage and retrieval system. One or more items or one or more storage containers may also be matched or aggregated together based on their respective unique identifications for transfer to a storage container in the grid framework structure of the second automated storage and retrieval system. Preferably, the control system is configured to aggregate or match a plurality of items from one or more storage containers in the first storage and retrieval system by aggregating their respective unique identities associated with at least a portion of one or more users or products. For example, if one or more items are baggage associated with one or more users, each baggage being assigned a unique identification comprising data associated with the user, the control system is configured to first identify their respective unique identities and then aggregate or match the baggage stored in the first storage and retrieval system based on aggregating their respective unique identities once identified.In the case of an assembly line, one or more items may be aggregated or collated together for assembly into at least one portion of a product at an assembly station before being transferred to a storage container within the grid framework structure of the second automated storage and retrieval system.

[0035] Preferably, the control system is configured to assign the aggregated respective unique identities associated with at least a portion of one or more users or products to the unique identities of the storage containers of the second automated storage and retrieval system. Thus, the storage containers in the grid structure of the second automated storage and retrieval system are prepared to receive the aggregated items from the one or more storage containers in the first automated storage and retrieval system. The unique identities of the storage containers of the second automated storage and retrieval system can correspond to the aggregated unique identities of the storage containers from the first automated storage and retrieval system based on data associated with the user, or another attribute common to one or more users, or an attribute associated with at least a portion of the product. For example, if the automated load handling system is an automated baggage handling system, the attribute can be data associated with travel details common to one or more users, such as a flight number. Thus, the unique identities of the storage containers from the first and second automated storage and retrieval systems can correspond to data associated with the flight details. Similarly, if one or more items in a storage container form a portion of at least a portion of a product, the unique identification of the one or more storage containers of the second automated storage and retrieval system may correspond to an aggregated unique identification of the storage containers from the first automated storage and retrieval system based on data associated with at least a portion of the product.

[0036] Preferably, the control system determines based on a corresponding unique identification of a storage container of the second automated storage and retrieval system on the at least one transport system: i) correlating unique identities associated with one or more users with corresponding unique identities of storage containers of a second automated storage and retrieval system in at least one transport system; ii) identifying one or more storage containers within the grid framework structure of the first automated storage and retrieval system based on correlating the unique identification with a grid location of the storage container within its respective grid framework structure of the first automated storage and retrieval system; iii) commanding a load handling device operable on a track system of the first automated storage and retrieval system to retrieve one or more storage containers from a grid location and move the one or more storage containers to at least one port column of the first automated storage and retrieval system; and further configured to instruct one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers to respective port columns of the first automated storage and retrieval system.

[0037] In response to the unique identification of the storage container of the second automated storage and retrieval system in the at least one transfer system (i.e., the buffer zone), the control system is configured to correlate the unique identification associated with the one or more users from the first automated storage and retrieval system with the corresponding unique identification of the storage container in the at least one transfer system. The storage container in the at least one transfer system is differently sized to accommodate one or more items from the storage container from the first automated storage and retrieval system, or the storage container itself. For example, the storage container from the second automated storage and retrieval system can be a unit load device (ULD) that is commonly used at airports to load baggage or cargo loads onto aircraft. Correlating the unique identification of the one or more storage containers from the first automated storage and retrieval system with the unique identification of the storage container from the second automated storage and retrieval system in the at least one transfer system can be based on, for example, flight data. In the case of a baggage handling system, the unique identification of the first and second automated storage and retrieval systems can additionally comprise data associated with a user-defined destination together with reservation data indicating a flight booked by the user.

[0038] After the control system correlates the storage containers associated with the unique identities of the storage containers from the first and second automated storage and retrieval systems, the control system then identifies one or more storage containers from the first automated storage and retrieval system for performing packing of the storage containers from the first automated storage and retrieval system into storage containers from the second automated storage and retrieval system on the at least one transfer system. The control system locates the one or more storage containers within the grid framework structure of the first automated storage and retrieval system based on correlating the unique identities with grid locations of the storage containers within their respective grid framework structure of the first automated storage and retrieval system. The control system then commands one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers from their locations and move the one or more storage containers to at least one port column of the first automated storage and retrieval system. In the at least one port column, the at least one transfer system is configured to transfer one or more storage containers or one or more items from a storage container from the at least one port column of the first automated storage and retrieval system to one or more storage containers from the at least one port column of the second automated storage and retrieval system.

[0039] The automated handling system of the present invention can be utilized as a baggage handling system in an airport, where the automated handling system is an automated baggage handling system where each of one or more items stored in one or more storage containers in the first automated storage and retrieval system is a baggage item. The unique identification associated with the user is baggage tag data, said baggage tag data comprising data associated with a user-specified destination together with reservation data indicative of travel data. In this case, each of the one or more storage containers in the second automated storage and retrieval system is a unit load device (ULD). The automated handling system is not limited to a baggage handling system and can be used in any automated handling system. For example, the automated handling system can be used to collect and store items associated with one or more users in a move. Similarly, the term "user" can be broadly interpreted to cover legal entities such as a company or partnership.

[0040] Where at least some of the products comprise an assembly of aggregated or collated items, preferably the control system further comprises, based on a unique identification associated with at least some of the products: i) identifying one or more storage containers comprising one or more items each forming a portion of at least a portion of the product; ii) locating the one or more storage containers within the grid framework structure of the first automated storage and retrieval system based on correlating the unique identification with a grid location of the storage container within its respective grid framework structure of the first automated storage and retrieval system; iii) by commanding one or more load handling devices operable on a track system of the first automated storage and retrieval system to retrieve one or more storage containers, each storage container comprising one or more items for assembly into at least a portion of a product, from its grid location and move the one or more storage containers to at least one port column of the first automated storage and retrieval system; The system is further configured to instruct one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers.

[0041] When assembling at least a portion of a product or a complete product, the control system identifies items or components needed to assemble at least a portion of the product. Once identified, the control system commands one or more load handling devices operable on the track system to locate storage containers with respect to their respective grid locations within the first automated storage and retrieval system, retrieve the one or more storage containers, and move the one or more storage containers to at least one port column of the first automated storage and retrieval system. The one or more items may then be assembled together at the assembly station before being transferred via the at least one transport system to a storage container in the second automated storage and retrieval system.

[0042] The present invention provides a method of handling one or more items within an automated load handling system in response to one or more storage containers from a second automated storage and retrieval system on at least one transport system, the method comprising: i) identifying one or more storage containers with one or more items by correlating unique identities associated with one or more users from a first automated storage and retrieval system with unique identities of one or more storage containers from a second automated storage and retrieval system in at least one transport system; ii) instructing one or more load handling devices operable on a track system of the first automated storage and retrieval system to retrieve one or more identified storage containers and move the one or more storage containers to at least one port of a grid framework structure of the first storage and retrieval system; iii) transferring one or more items from the identified one or more storage containers to one or more storage containers from a second automated storage and retrieval system on at least one transfer system; iv) instructing one or more load handling devices operable on a track system of the second automated storage and retrieval system to move one or more storage containers from the at least one transport system to storage columns of a grid framework structure of the second automated storage and retrieval system; The present invention further provides a method comprising:

[0043] In preparation for transferring one or more items or storage containers from the first automated storage and retrieval system to one or more storage containers of the second automated storage and retrieval system, the method further comprises instructing one or more load handling devices operable on a track system of the second automated storage and retrieval system to retrieve the one or more storage containers from the grid framework structure of the second automated storage and retrieval system to at least one transfer system based on unique identification of the one or more aggregated storage containers from the first automated storage and retrieval system.

[0044] The present invention relates to a method of assembling one or more items from an automated load handling system according to the present invention to form at least a portion of a product, comprising the steps of: i) identifying one or more storage containers from a first automated storage and retrieval system, the storage containers comprising one or more items having a unique identification associated with at least a portion of the products; ii) commanding one or more load handling devices operable on a track system of the first automated storage and retrieval system to retrieve one or more storage containers, each storage container comprising one or more items for assembly into at least a portion of a product, from its grid location and to move the one or more storage containers to at least one port column of the first automated storage and retrieval system; iii) assembling one or more items from the one or more storage containers to form at least a portion of a product; iv) transferring at least a portion of the products to one or more storage containers from the second automated storage and retrieval system on at least one transfer system; v) instructing one or more load handling devices operable on a track system of the second automated storage and retrieval system to move one or more storage containers from the at least one transport system to storage columns of a grid framework structure of the second automated storage and retrieval system; The present invention further provides a method comprising:

[0045] The automated handling system will now be described in detail with reference to an example. [Brief description of the drawings]

[0046] [Figure 1] 1 is a schematic diagram of an automated handling system having first and second automated storage and retrieval systems. [Diagram 2] Schematic diagram of a grid framework structure and containers. [Diagram 3] 2 is a schematic diagram of the upper track of the grid framework structure shown in FIG. 1 . [Figure 4] 3 is a schematic diagram of a load handling device on top of the grid framework structure shown in FIG. 2 . [Diagram 5] FIG. 2 is a schematic diagram of a single load handling device with the container lifting means in a lowered configuration. [Figure 6]FIG. 2 is a schematic cutaway view of a single load handling device with container lifting means in raised and lowered configurations. [Figure 7] 1 is a schematic diagram of a first automated storage and retrieval system comprising a grid framework structure, storage containers and a load handling device. [Figure 8] 1 is a schematic diagram of a second automated storage and retrieval system comprising a grid framework structure, storage containers and a load handling device. [Figure 9] 1 is a schematic diagram of an automated handling system having first and second automated storage and retrieval systems. [Figure 10] 2A-2C are different schematic diagrams of an automated handling system having first and second automated storage and retrieval systems; [Figure 11(a)] Schematic diagram of a pick station. [Figure 11(b)] FIG. 8 is a perspective view of the storage container of FIG. [Figure 12] 1 is a schematic diagram of an automated handling system having first and second automated storage and retrieval systems. [Figure 13] 1 is a schematic diagram of an automated handling system having first and second automated storage and retrieval systems. [Figure 14] 1 is a schematic diagram of an automated handling system having first and second automated storage and retrieval systems. [Figure 15] 1 is a block diagram illustrating components of an automated handling system in accordance with an exemplary embodiment of the present invention. [Figure 16] 1 is a flow diagram illustrating a process for assigning unique identification to storage containers within a grid framework structure. [Figure 17] 4 is a flow diagram illustrating an exemplary embodiment of sorting of storage containers in an automated handling system. [Figure 18] 1 is a flow diagram illustrating the application of the automated handling system as an assembly system. [Figure 19] FIG. 2 illustrates an exemplary embodiment of an assembly station. [Figure 20] FIG. 20 illustrates an automated assembly system incorporating the assembly station of FIG. 19. [Figure 21] 12 illustrates the pick station of FIG. 11 adjacent to a second automated storage and retrieval system. [Figure 22] FIG. 13 illustrates a pick station adjacent to a second automated storage and retrieval system. [Diagram 23] 1 is a schematic diagram of an automated handling system having first and second automated storage and retrieval systems and a transport system. [Figure 24] Schematic of the rear of the automated handling system showing storage containers being loaded onto a cargo dolly. [Diagram 25] 1 is a schematic plan view of an automated handling system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] The automated handling system comprises two or more automated storage and retrieval systems, each of which comprises a grid framework structure and one or more load handling devices, as described in more detail below. The storage containers of the automated storage and retrieval systems are sized differently, and the storage containers or items within the storage containers are collated and / or sorted as they are transferred from one automated storage and retrieval system to another.

[0048] The present invention is described below with reference to a first automated storage and retrieval system and a second automated storage and retrieval system, where the grid openings and storage containers and load handling devices of the second automated storage and retrieval system are larger than the grid openings and storage containers and load handling devices of the first automated storage and retrieval system.

[0049] The term "large grid opening" is used to describe the grid opening of the second automated storage and retrieval system, and the term "small grid opening" is used to describe the grid opening of the first automated storage and retrieval system. The term "large container" or "large storage container" is used to describe the storage container of the second automated storage and retrieval system, and the term "small container" or "small storage container" is used to describe the storage container of the first automated storage and retrieval system. The term "large load handling device" is used to describe the load handling device of the second automated storage and retrieval system, and the term "small load handling device" is used to describe the load handling device of the first automated storage and retrieval system. It will be understood that an automated handling system having two automated storage and retrieval systems as described below is one example of the claimed invention, and that the invention also encompasses automated handling systems with three or more automated storage and retrieval systems and with three or more sizes of grid openings and storage containers and load handling devices.

[0050] The larger storage container of the second automated storage and retrieval system may be sized such that some of the smaller storage containers of the first automated storage and retrieval system can be accommodated inside the larger container of the second automated storage and retrieval system. For example, the dimensions of the larger storage container may be selected to be an integer multiple of the dimensions of the smaller storage containers plus some clearance allowance. For example, the length, width, and height of the larger storage container may be twice the length, width, and height of the smaller storage containers, respectively, such that eight smaller storage containers can be accommodated within one larger storage container.

[0051] As an alternative to placing a smaller storage container inside a larger container, one or more items may be picked from the smaller container into the larger storage container. In some applications, the storage container may be a tray rather than a deep sided container to facilitate removing or placing items into the container.

[0052] The automated handling system comprises one or more transfer systems for transferring storage containers or items within the storage containers from one automated storage and retrieval system to another such system. For purposes of this description, an example is given in which a storage container from a first automated storage and retrieval system is transferred to a second automated storage and retrieval system. [Application example] There are many possible applications for the automated handling system. For example, the automated handling system may be an automated baggage handling system for handling baggage for passenger transportation. For example, the storage containers in one of the automated storage and retrieval systems may be shipping containers and the automated handling system may be for preparing items for shipping in the shipping containers. The storage containers may be for storing personal belongings or furniture for a customer move, or for placing belongings in a long or short term storage facility. The automated handling system may be for fulfilling vehicle orders for a showroom or retailer or fleet customer, and the storage containers may include vehicles. The automated handling system may be for fulfilling customer orders (e.g. grocery orders) and matching the orders into larger shipments that are sent to spokes of a hub and spoke distribution network. The automated handling system may be for prefabricated or modular buildings. The automated handling system may be an automated assembly line, where parts from a first automated storage and retrieval system are assembled and the assembled products are transferred for storage in a second automated storage and retrieval system. These applications are merely non-limiting examples and the automated handling system may be used to handle any type of goods or products or items for retail or distribution or any other application.

[0053] 1 shows diagrammatically an automated handling system 50 having a first automated storage and retrieval system 52 and a second automated storage and retrieval system 54. It can be clearly seen from FIG. 1 that the grid framework structures 1 of the two automated storage and retrieval systems are of different sizes, with the storage columns 10, storage containers 9, spacing between uprights 3, grid openings or apertures 15, and load handling devices 31 all being relatively larger in the second automated storage and retrieval system than in the first automated storage and retrieval system. In the particular embodiment shown in FIG. 1, the first automated storage and retrieval system 52 is configured to store smaller storage containers 9 and the second automated storage and retrieval system 54 is configured to store larger storage containers 9.

[0054] FIG. 1 also shows a transfer system 56 positioned between the first automated storage and retrieval system 52 and the second automated storage and retrieval system 54. The transfer system is used to transfer storage containers or items within the storage containers from one automated storage and retrieval system to another. The transfer system may comprise a conveyor system comprising one or more conveyor units extending between the first and second automated storage and retrieval systems. One or more port columns 58 in the second automated storage and retrieval system 54 are used to transport large storage containers 9 into the grid framework structure 1 of the second automated storage and retrieval system 54 and out of it to one of the transfer systems 56. The one or more port columns 58 may be defined as an exit port column configured to drop off one or more storage containers into the transfer system and as an entrance port column configured to pick up one or more storage containers from the transfer system. In a similar manner, one or more port columns 58 (not shown) in the first automated storage and retrieval system 52 are used to transport smaller storage containers 9 into and out of the grid framework structure 1 of the first automated storage and retrieval system 52 to the same transport system 56. Items can then be transferred between the larger and smaller storage containers, or smaller storage containers 9 can be placed into or removed from the larger storage containers 9. [Automated storage and retrieval system] A preferred embodiment of the automated storage and retrieval system is described below with reference to Figures 2-6.

[0055] FIG. 2 shows a grid framework structure 1 comprising upright members 3 and horizontal members 5, 7 supported by the upright members 3. The horizontal members 5 extend parallel to each other and parallel to the illustrated x-axis. The horizontal members 7 extend parallel to each other, parallel to the illustrated y-axis and transverse to the horizontal members 5. The upright members 3 extend parallel to each other, parallel to the illustrated z-axis and transverse to the horizontal members 5, 7. The horizontal members 5, 7 form a grid pattern defining a plurality of grid spaces or grid cells 14, each of which defines a grid opening 15. In the illustrated example, the containers 9 are arranged in stacks 11 below the grid cells 14 defined by the grid pattern, one stack 11 of containers 9 per cell 14. The grid openings 15 provide space for the storage containers 9 to exit the grid framework structure.

[0056] In the illustrated example, stacks 11 of containers 9 occupy storage columns 10, where each storage column 10 underlies one grid cell 14. A storage column may be defined as the space between four uprights 3, one upright 3 at each corner of the storage column.

[0057] FIG. 3 shows an enlarged plan view of a section of a track system 13 forming part of the grid framework structure 1 shown in FIG. 2 and located on top of the horizontal members 5, 7 of the grid framework structure 1 shown in FIG. 2. The track system 13 may be provided by the horizontal members 5, 7 themselves (e.g. formed in or on a surface of the horizontal members 5, 7) or by one or more additional components attached to the top of the horizontal members 5, 7. For example, the horizontal members 5, 7 may comprise rails or tracks or the rails or tracks may be attached to the top of the horizontal members. The track structure 13 shown comprises X-direction rails or tracks 17 and y-direction rails or tracks 19, i.e. a first set of tracks 17 extending in the x-direction and a second set of tracks 19 extending in the y-direction transverse to the tracks 17 in the first set of tracks 17. The tracks 17, 19 define grid openings 15 at the centres of the grid cells 14. The grid openings 15 are sized to allow a container 9 located beneath a grid cell 14 to be lifted and lowered through the grid opening 15. The x-direction tracks 17 are provided in pairs separated by channels 21 and the y-direction tracks 19 are provided in pairs separated by channels 23. Other arrangements of the track structures may also be possible.

[0058] Figure 4 shows multiple load handling devices 31 moving on top of the storage structure 1 shown in Figure 2. The load handling devices 31, which may also be referred to as robots 31 or bots 31, are provided with a set of wheels for engaging with corresponding x- or y-direction tracks 17, 19 to enable the bots 31 to navigate across the track structure 13 and reach a designated grid cell. The illustrated pair of tracks 17, 19 separated by channels 21, 23 enables the bots 31 to occupy adjacent grid cells (or pass each other) without colliding with each other.

[0059] 5, the bot 31 comprises a body 33 with one or more components mounted within or on it that enable the bot 31 to perform its intended functions. These functions may include moving across the grid framework structure 1 on the track structure 13 and raising or lowering containers 9 (e.g., from or onto stacks 11) so that the bot 31 can pick up or deposit containers 9 at specific locations defined by the grid pattern.

[0060] The illustrated bot 31 comprises a first and a second set of wheels 35, 37 mounted on the body 33 of the bot 31 and enabling the bot 31 to move in the x and y directions along the tracks 17 and 19, respectively. In particular, two wheels 35 are provided on the short side of the bot 31 visible in FIG. 5 and two further wheels 35 are provided on the opposite short side of the bot 31 (the side and the two further wheels 35 are not visible in FIG. 5). The wheels 35 are rotatably mounted on the body 33 of the bot 31 to engage with the track 17 and enable the bot 31 to move along the track 17. In the same manner, two wheels 37 are provided on the long side of the bot 31 visible in FIG. 5 and two further wheels 37 are provided on the opposite long side of the bot 31 (the side and the two further wheels 37 are not visible in FIG. 5). The wheels 37 are rotatably mounted on the body 33 of the bot 31 to engage with the track 19 and enable the bot 31 to move along the track 19.

[0061] The bot 31 also comprises a container lifting means 39 configured to raise and lower the container 9. The illustrated container lifting means 39 comprises four tapes or reels 41, which are connected at their lower ends to a container engagement assembly 43. The container engagement assembly 43 comprises engagement means configured to engage features of the container 9 (e.g. may be provided at a corner of the assembly 43, near the tapes 41). For example, the container 9 may be provided with one or more apertures in its upper surface with which the engagement means can engage. Alternatively or additionally, the engagement means may be configured to hook under a rim or lip of the container 9 and / or may be configured to clamp or grip the container 9. The tapes 41 may be wound up or down to raise or lower the container engagement assembly when required. A winch mechanism 40, which may be one or more motors or other means, may be provided to effect or control the winding up or down of the tapes 41.

[0062] As seen in FIG. 6, the body 33 of the illustrated bot 31 has an upper portion 45 and a lower portion 47. The upper portion 45 is configured to accommodate one or more operating components (not shown). The lower portion 47 is disposed below the upper portion 45. The lower portion 47 comprises a container receiving space or cavity for accommodating at least a portion of the container 9 raised by the container lifting means 39. The container receiving space is sized so that the container 9 can fit sufficiently inside the cavity to allow the bot 31 to move across the track structure 13 on top of the grid framework structure 1 without catching the lower surface of the container 9 on the track structure 13 or another part of the grid framework structure 1. When the bot 31 reaches its intended destination, the container lifting means 39 controls the tape 41 to lower the container gripping assembly 43 and the corresponding container 9 out of the cavity in the lower portion 47 and into the intended position. The intended location may be a stack 11 of containers 9 or an exit point of the grid framework structure 1 (or an entry point of the grid framework structure 1 if the bot 31 is moving to collect containers 9 for storage within the grid framework structure 1). A port column is an example of an entry and exit point. In the illustrated example, the upper and lower portions 45, 47 are separated by a physical divider, but in other embodiments the upper and lower portions 45, 47 may not be physically separated by a unique component or part of the body 33 of the bot 31.

[0063] In some embodiments, the container receiving space of the bot 31 may not be within the body 33 of the bot 31. For example, in some embodiments, the container receiving space may be adjacent to the body 33 of the bot 31, e.g., in a cantilever arrangement where the weight of the container to be lifted is balanced with the weight of the body 33 of the bot 31. In such an embodiment, the frame or arm of the container lifting means 39 may project horizontally from the body 33 of the bot 31, and the tape / reel 41 may be arranged at respective positions on the projecting frame / arm and configured to be raised and lowered from these positions to raise and lower the container into the container receiving space adjacent the body 33. The height at which the frame / arm is mounted on and projects from the body 33 of the bot 31 may be selected to provide a desired effect. For example, it may be preferable for the frame / arm to project higher on the body 33 of the bot 31 to allow a larger container (or multiple containers) to be lifted into the container receiving space below the frame / arm. Alternatively, the frame / arm may be arranged to protrude below the body 33 (but high enough to accommodate at least one container between the frame / arm and the track structure 13) to keep the center of mass of the bot 31 downward when containers are loaded onto the bot 31.

[0064] To enable the bot 31 to move in a first and second direction on different wheels 35, 37, the bot 31 includes a wheel positioning mechanism for selectively engaging a first set of wheels 35 with a first set of tracks 17 or a second set of wheels 37 with a second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 35 and / or the second set of wheels 37 relative to the body 33, thereby enabling the load handling device 31 to selectively move in either a first direction or a second direction across the tracks 17, 19 of the grid framework structure 1.

[0065] The wheel positioning mechanism may include one or more linear actuators, rotary components, or other means for raising and lowering at least one set of wheels 35, 37 relative to the body 33 of the bot 31 to move the at least one set of wheels 35, 37 out of and into contact with the tracks 17, 19. In some examples, only one set of wheels is configured to be raised and lowered, and the act of lowering one set of wheels may effectively lift the other set of wheels out of contact with the corresponding tracks, while the act of raising one set of wheels may effectively lower the other set of wheels into contact with the corresponding tracks. In other examples, both sets of wheels may be raised and lowered, which advantageously means that the body 33 of the bot 31 remains at substantially the same height, and therefore the weight of the body 33 and components mounted thereon does not have to be lifted and lowered by the wheel positioning mechanism. [Automated storage and retrieval systems of different sizes] 7 shows a schematic representation of an embodiment of a first automated storage and retrieval system 52. The first automated storage and retrieval system 52 comprises a grid framework structure 1 and a load handling device 31. As explained in more detail above, the load handling device 31 operates on top of the grid framework structure 1 and traverses the track system 13 by means of two sets of wheels 35, 37 that engage with the x-direction tracks 17 and the y-direction tracks 19 respectively. The load handling device 31 is configured to retrieve and replace containers 9 from a stack 11 of containers in a storage column 10 through the grid openings 15.

[0066] 8 shows diagrammatically a second automated storage and retrieval system 54. The second automated storage and retrieval system comprises a grid framework structure 1 and a load handling device 31 and operates in a similar manner to the first automated storage and retrieval system.

[0067] In a second automated storage and retrieval system 54 shown in Figure 8, the storage container 9 is housed inside a cage 12 (see Figure 11(a)). As an alternative to the container engagement assembly 43 directly engaging a feature of the storage container 9 as explained above in relation to Figure 5, the container engagement assembly 43 may engage a feature of the cage 12. For example, the cage 12 may be provided with one or more apertures in its upper side with which the engagement means may engage. Alternatively or additionally, the engagement means may be configured to hook under a bar of the cage 12 and / or to clamp or grip the cage 12.

[0068] 7 is a tray rather than a deep sided container to facilitate retrieving or placing items into or from the container. This alternative embodiment of the storage container 9 can be advantageous in some applications, for example, applications in which individual items are transferred from a smaller storage container of the first automated storage and retrieval system 52 to or from a larger storage container of the second automated storage and retrieval system 54. [Transportation system] Figure 9 shows a schematic representation of an embodiment of an automated handling system 50 having a first and a second storage and retrieval system 52, 54 as shown in Figures 7 and 8, respectively. It can be seen from Figure 9 that the two grid framework structures 1 of the first and second automated storage and retrieval systems 52, 54 are of different sizes and scales. The storage containers 9, the load handling devices 31 and the grid apertures 15 of the second automated storage and retrieval system 54 are all larger in height and / or length and / or width than the respective storage containers 9, the load handling devices 31 and the grid apertures 15 of the first automated storage and retrieval system 52. The larger storage containers 9 of the second automated storage and retrieval system 54 have a larger volume capacity than the storage containers of the first automated storage and retrieval system 52.

[0069] FIG. 10 shows a schematic representation of a different view of the automated handling system 50, having first and second storage and retrieval systems 52, 54 and a transfer system 56. The storage containers 9 from the second automated storage and retrieval system 54 can be seen on the transfer system 56. The large storage containers 9 are transported into and out of the grid framework structure 1 of the second automated storage and retrieval system 54 via one or more port columns 58. In the illustrated embodiment, the transfer system 56 transports the large storage containers 9 of the second automated storage and retrieval system 54 to a position adjacent one or more pick stations 64 of the first automated storage and retrieval system 52, where one or more items or storage containers picked from the first automated storage and retrieval system 52 are transferred to one or more storage containers from the second automated storage and retrieval system 54. The transfer system 56 comprises at least one conveyor system 60. In the illustrated embodiment, the at least one conveyor system comprises three conveyor units 62 that extend into and out of port columns of the grid framework structure of the second automated storage and retrieval system.

[0070] The first automated storage and retrieval system 52 is provided with one or more port columns 58 for transferring the small storage containers 9 to a location adjacent one or more pick stations 64. At the pick stations 64, items are transferred between the small storage containers 9 of the first automated storage and retrieval system 52 and the large storage containers 9 of the second automated storage and retrieval system 54. Items may be transferred from the small storage containers into the large storage containers or from the large storage containers into the small storage containers. In the illustrated embodiment, the pick station 64 is provided with one or more robotic arms 76 configured to pick up items from the small storage containers 9 and place them in the large storage containers 9 on the conveyor system 60. The transfer system 56 further comprises a decanting station configured to receive items picked from the one or more storage containers at the pick stations 64. Thus, items picked from a storage container at the pick station from the first automated storage and retrieval system 52 are transferred to a storage container at the decant station for storage in the second automated storage and retrieval system. [Conveyor system] As explained above in the embodiment of the transfer system 56 shown in Figure 10, at least one conveyor system 60 comprises three conveyor units 62. The three conveyor units are referred to as an exit conveyor unit 72, an entrance conveyor unit 74, and a transfer conveyor unit 73.

[0071] The conveyor system 60 transports the storage bulk containers 9 from the port column of the second automated storage and retrieval system 54 to the picking station 64 delivered from the first automated storage and retrieval system 52 and then back to the port column of the second automated storage and retrieval system. In one embodiment, the storage bulk containers or containers may be picked up by a load handling device 31 operable on the grid framework structure 1 and vertically stacked for return to either its original destination in the grid framework structure 1 or a new destination in the grid framework structure 1. In one embodiment of the invention, at least one conveyor system 60 of the transfer system 56 comprises a plurality of conveyor units 62, namely an entrance conveyor unit 74, at least one transfer conveyor unit 73, and an exit conveyor unit 72 as discussed above, and is arranged to transfer the storage bulk containers or containers 9 from the port column of the automated storage and retrieval system to a buffer zone 70. The storage bulk containers or containers 9 are stopped in the buffer zone 70. The pick station 64 and / or the decant station are located in the buffer zone 70 such that storage containers in the buffer zone 70 may be accessed from the pick station 64 and / or the decant station. The conveyor units 62 are positioned adjacent to one another or connected to one another such that storage containers 9 are transported from one conveyor unit to an adjacent conveyor unit as they progress along the conveyor system 60. In the embodiment of the at least one conveyor system shown in FIG. 10, the buffer zone 70 is a transfer conveyor unit 73. In other embodiments, a buffer zone 70 may be provided that is separate from and adjacent to the at least one conveyor system 60.

[0072] The entrance conveyor unit 74, the transfer conveyor unit 73, and the exit conveyor unit 72 are at the same height. Each conveyor unit 62 may comprise any suitable arrangement of belts, chains, and / or rollers well known in the art of conveyor systems. In one embodiment, the entrance conveyor unit 74, the transfer conveyor unit 73, and the exit conveyor unit 72 comprise multiple roller conveyors for transporting the storage bulk container or container along a path on the conveyor system 60. The entrance conveyor unit 74, the transfer conveyor unit 73, and the exit conveyor unit 72 are arranged such that the path of the transport direction of the storage bulk container or container (indicated by the arrows in FIG. 10) can follow a U-shaped path or an L-shaped path. The conveyor system 60 may be mounted on a roller frame. The entrance conveyor unit 74 and the exit conveyor unit 72 are arranged to accommodate a single storage container 9 at the top.

[0073] The path or transport direction of the inlet conveyor unit 74 may be parallel to and opposite to the path or transport direction of the exit conveyor unit 72, such that the path or transport direction of the at least one transfer conveyor unit 73 is perpendicular to or orthogonal to the path or transport direction of both the inlet conveyor unit 74 and the exit conveyor unit 72. In other words, the storage bin or container 9 travels a U-shaped path along the conveyor system 60, where the storage container 9 leaves the automated storage and retrieval system and returns into the automated storage and retrieval system via at least one transfer conveyor unit 73, i.e. the storage container 9 changes direction twice along the conveyor system 60. Optionally, the path or transport direction of the inlet conveyor unit 74 extends longitudinally in the same transport direction of the transfer conveyor unit 73, i.e. the inlet conveyor unit 74 is an extension of the transfer conveyor unit 73. Here, the path or transport direction of the inlet conveyor unit 74 is perpendicular to or orthogonal to the path or transport direction of both the transfer conveyor unit 73 and the exit conveyor unit 72 such that the storage bulk container 9 travels an L-shaped path along the conveyor system 60, i.e., the storage bulk container 9 changes direction once as it travels from the port column to the buffer zone. In one embodiment, the conveyor system is arranged such that the path or transport direction of the storage bulk container can follow both a U-shaped path and an L-shaped path along the conveyor system. The combination of U-shaped and L-shaped paths allows multiple storage bulk containers or containers 9 to be lined up in the buffer zone 70 before being lifted towards the grid framework structure 1 for subsequent retrieval by a load handling device 31 operable on a track system 13 on the grid framework structure 1. This allows multiple storage bulk containers or containers 9 to be processed by the transfer system 56. The combination of U-shaped and L-shaped paths allows a relatively small width of the transfer system 56 for processing multiple storage bulk containers or containers 9 in the buffer zone.

[0074] The transfer conveyor unit 73 extends between an entrance conveyor unit 74 and an exit conveyor unit 72 and may comprise a plurality of conveyor units 62 arranged adjacent to one another in a horizontal plane such that the storage bins or containers 9 are transported from one conveyor unit 62 to an adjacent conveyor unit 62. Alternatively, the at least one transfer conveyor unit 73 may be a single conveyor unit extending between the entrance conveyor unit 74 and the exit conveyor unit 72. Typically, one or more of the rollers of at least one of the conveyor units 62 are provided with an integrated drive motor, while the remaining rollers may be connected by belts to the drive rollers or they may be passive.

[0075] In another embodiment, an additional conveyor unit, called a redirection conveyor unit 75, is integrated into the conveyor system 60. The additional conveyor unit or redirection conveyor unit (not shown) comprises one or more rollers or belts or chains arranged transversely disposed between the rollers of the transfer conveyor unit 73 or arranged to mesh between the rollers of the transfer conveyor unit 73 and to be driven transversely to the transport direction of the transfer conveyor unit 73. The additional conveyor unit or redirection conveyor unit is lowered or raised by a lifting mechanism relative to the rollers of the transfer conveyor unit 73 such that in the raised position the redirection conveyor unit contacts the storage container 9, thereby causing the redirection conveyor unit to pull or draw the storage bin from the transfer conveyor unit 73 onto a separate surface in the buffer zone 70. The separate surface in the buffer zone 70 comprises an intermediate holding facility (not shown). Although the particular embodiment describes a lifting mechanism for engaging the redirecting conveyor unit 75 with a storage bin on the conveyor unit, other redirecting conveyor units, such as conveyor balls and rail mounted trolleys, commonly known in the art of conveyor systems, can be utilized in the present invention.

[0076] A control system is used to actuate the movement of the conveyor units. The control system may send a signal to one or more drive motors to activate the motors and cause movement of the conveyor units. Alternatively, or in addition, one or more sensors may be used to detect the presence of one or more storage containers, and the sensors may send a signal to the control system, which may actuate the one or more drive motors to move one or more of the conveyor units.

[0077] The intermediate holding facility that is part of the buffer zone 70 is configured to temporarily hold one or more items or storage containers 9 in the transfer system 56. These can be storage containers from the first automated storage and retrieval system 52 and / or the second automated storage and retrieval system 54, or items from one or more storage containers. For example, the intermediate holding facility can hold a large storage container from the second automated storage and retrieval system 54, while a small storage container from the first automated storage and retrieval system 52 or items from the small storage container are picked and transferred into the large storage container (see FIG. 11(a)).

[0078] The use of an intermediate holding facility can improve the efficiency of the automated handling system by eliminating the need for storage containers from the first and second automated storage and retrieval systems to be in the transport system at the same time. For example, an item from a small storage container of the first automated storage and retrieval system 52 can be picked from the storage container to the intermediate holding facility, where the item can remain until a large storage container from the second automated storage and retrieval system 54 reaches the buffer zone 70 of the transport system. After the item has been picked, the small storage container of the first automated storage and retrieval system can be returned to the grid framework structure of the first automated storage and retrieval system 52 without having to wait for the large storage container from the second automated storage and retrieval system 54 to be ready to receive the item. This improves efficiency because the storage container does not wait and does not prevent the next storage container from being processed through the transport system.

[0079] Although the at least one conveyor system in the particular embodiment of the invention in FIG. 10 shows one conveyor system extending from the exit port column to the entry port column of the grid framework structure of the second automated storage and retrieval system, the at least one conveyor system may comprise a first conveyor system for transporting storage containers to and from the grid framework structure of the first automated storage and retrieval system and a second conveyor system for transporting storage containers to and from the grid framework structure of the second automated storage and retrieval system. Each of the first and second conveyor systems comprises an exit conveyor unit, an entry conveyor unit, and a transfer conveyor unit, where the transfer conveyor unit extends between the exit conveyor unit and the entry conveyor unit as discussed above. Thus, the first conveyor system transports storage bins or containers 9 from the exit port column of the first automated storage and retrieval system to the picking station 64 and then back to the entry port column of the first automated storage and retrieval system. Similarly, the second conveyor system transports storage bins or containers 9 from the exit port column of the second automated storage and retrieval system to the decanting station and then back to the entrance port column of the second automated storage and retrieval system. The pick station is located or positioned between the first and second conveyor systems such that one or more items can be picked from a storage container on the first conveyor system and disposed or transferred into a storage container on the second conveyor system.

[0080] In another exemplary embodiment of the present invention, the at least one conveyor system comprises at least one conveyor unit extending directly between at least one port column of the grid framework structure of the first automated storage and retrieval system and at least one port column of the grid framework structure of the second automated storage and retrieval system. Thus, the first and second automated storage and retrieval systems share the same conveyor system extending between their respective grid framework structures. As a result, the entrance conveyor unit, the exit conveyor unit, and the transfer conveyor unit are shared between the first automated storage and retrieval system and the second automated storage and retrieval system. [Weighing cell] If the conveyor system 60 comprises multiple conveyor units 62, one or more of the conveyor units 62 may be equipped with a weighing cell, or alternatively, the weighing cell may be located anywhere along the conveyor system. The weighing cell is connected to at least one conveyor unit 62 and is arranged to weigh the storage containers 9. Alternatively or additionally, the intermediate holding facility and / or the picking station 64 may be provided with one or more weighing cells. The weighing cell may be a load cell or any other weighing cell commonly known to those skilled in the art. The control panel may be configured to display the weight of the storage container 9 when an item or other container is picked up from or loaded into the storage container. For example, when operated at the pick station, the weighing cell measures the weight of the storage container 9 when one or more items are picked from the storage container 9. The control system is used to monitor the weight of the storage container when an item is picked from the storage container. This allows the control system to keep track of the weight of each of the storage containers stored within the grid framework structure.

[0081] The weighing cells prevent overloading of the storage containers 9, which may impede the ability of the bulk container lifting devices and / or lifting mechanisms of the load handling devices to lift the storage bulk containers or containers. The lifting mechanisms of the load handling devices and / or motors of the bulk container lifting devices are rated to carry a predetermined weight. Once the predetermined weight is reached, an indication on the control panel provides a notice to the operator, for example via a display panel, or sends a signal to the control system to indicate that the weight of the particular storage bulk container or container has been reached and no more items can be added to the storage bulk container until it is transported back into the automated storage and retrieval system. Additionally or alternatively, the lifting mechanisms of one or more bulk container lifting devices may be equipped with weighing cells for weighing the storage bulk containers or containers as they are lifted towards the grid framework structure. [Large container lifting device] Optionally, to prevent one or more storage bins or containers from getting stuck in the transfer system 56, the transfer system 56 additionally comprises one or more bin lifting devices to allow vertical accumulation of one or more storage bins. The bin lifting device comprises a lifting arm and a lifting mechanism. In a particular embodiment of the invention, the bin lifting device comprises a pair of lifting arms or two lifting arms. The space between the lifting arms is wide enough to allow the conveyor unit 62 to pass between the lifting arms as the lifting arms descend and pass the conveyor unit 62. In use, the lifting arms descend to a lowest level below the conveyor unit 62 so that they can engage with the bottom wall of the storage bin on the conveyor unit. The storage bin or container is lifted from a lowest position on the conveyor unit 62 to a top position towards the grid structure 1 such that the storage bin is vertically spaced from the conveyor unit 62. This allows a second storage bin or container to enter conveyor unit 62 and be stacked vertically below the storage bin or container above.

[0082] The bulk container lifting device may be located above an inlet conveyor unit 74 that transports the storage container into the grid framework structure 1. The inlet conveyor unit 74 and the bulk container lifting device may be located in a port column 58 of the grid framework structure 1. The storage bulk container in the uppermost position waits until a load handling device 31 operable on the grid framework structure 1 at an upper level can retrieve the storage bulk container or container 9 through the port column 58. More specifically, the gripping device 43 of the load handling device 31 can grip the storage bulk container or container 9 at the uppermost level and lift the storage bulk container or container 9 into the container receiving space of the load handling device 31. A sensor detects the removal of a storage large container at the top level, thereby sending a signal to a control system or controller to lower a lifting arm beneath a second storage large container or container resting on the inlet conveyor unit 74, which is then lifted to the top level to allow a third storage large container or container lined up on the conveyor system to be lifted by the large container lifting device.

[0083] The bulk container lifting device may comprise multiple pairs of lifting arms that are vertically spaced apart to allow multiple storage bulk containers to be vertically accumulated at different heights. For example, a first pair of lifting arms may be arranged to lift a first storage bulk container to a first height, a second pair of lifting arms may be arranged to lift a second storage bulk container to a second height, and so on. This allows multiple storage bulk containers to be vertically accumulated at different heights before being transported into the grid framework structure for storage. In addition to this, one or more bulk container lifting devices may be arranged adjacent to each other. To save space and reduce the footprint of the transfer system 56, a first bulk container lifting device may be arranged at an end of the conveyor system 60 such that storage bulk containers or containers may be transported into the first bulk container lifting device along the same path of the conveyor system 60. When the first bulk container lifting device is fully occupied, the conveyor system may be commanded to redirect the storage containers into a second bulk container lifting device that is vertically adjacent to the direction of the conveyor system 60. This may be achieved by controlling the movement of the container using the redirecting conveyor unit 75 as described above to transport the storage large container into the second large container lifting device, where the control system or a separate controller monitors the occupancy of the first large container lifting device and the second large container lifting device and depending on their occupancy decides whether to transport the storage large container into the first large container lifting device or into the second large container lifting device. The occupancy of the large container lifting device is determined by one or more sensors to detect the presence of the storage large container or container in the large container lifting device. Examples of sensors include, but are not limited to, proximity sensors such as optical sensors.

[0084] Having multiple large container lifting devices allows for greater throughput of stored large containers or containers by the transport system 56. The number of large container lifting devices is not limited to two, and the inlet conveyor unit 74 can be arranged to allow for multiple large container lifting devices at the receiving end of the transfer conveyor unit.

[0085] The one or more large vessel lifting devices may include at least two guides for vertically guiding the storage large vessel or container as it is lifted by the lifting arms. In one embodiment, four guides are provided at the four corners of the large vessel lifting device. The guides are received in the port columns 58. Similarly, a bracket may be used to connect the top of the large vessel lifting device to the port columns of the grid framework structure 1. The bracket includes guides for guiding the storage large vessel or container into the port columns. This allows the large vessel lifting device to be a separate part of the grid framework structure and thus the ability to be retrofitted to an existing grid framework structure. The one or more large vessel lifting devices include side walls or panels attached to the exterior of at least a portion of the guides to enclose the large vessel lifting device and prevent components of the large vessel lifting device, such as the lifting arms, from being exposed. [Pick Station] FIG. 11(a) shows an embodiment of a pick station or picking station 64 in more detail. A conveyor unit 62 of a conveyor system 60 transports a large storage container 9 from the second automated storage and retrieval system 52 to a location adjacent to the pick station 64 so that items or small storage containers 9 at the pick station can be transferred to the large storage containers 9. The small storage containers 9 are transported to the pick station by one or more port columns 58 of the first automated storage and retrieval system 52 (not shown). The small storage containers 9 in this embodiment are shallow trays 8 (see FIG. 11(b)) and items 6 are stored in the trays 8 (see FIG. 11(b)). For purposes of the present definition, the term "shallow" tray is taken to mean a shallow container having a raised or upwardly extending lip or rim. The upwardly extending rim 8b of the shallow tray 8 ensures that a gripping device 39 of a load handling device 31 operable on a track system 13 can grip a storage container 9 with the shallow tray 8 and lift it out of the stack 11. In an exemplary embodiment of the invention, the gripping device 39 releasably engages the upwardly extending rim of the shallow tray 8. The upwardly extending rim 8b also prevents items 6 from falling out of the shallow tray.

[0086] One problem with storing one or more items 6 in a conventional box-like structure of storage containers 9 with a bottom wall, opposing upwardly extending side walls, and end walls is that when held in the stack 11, the contents of the storage container 9 can only be accessed from the storage container mouth or open end. This requires a load handling device 31 operable on the track system 13 to lift the storage container 9 from its grid position to gain access to the contents of the storage container 9. However, if one or more of the load handling devices 31 become inoperable on the track system 13, access to the interior of the storage containers held in the stack 11 can be difficult. In a worst case scenario, one or more storage containers 9 need to be lifted out of the stack 11 to retrieve and thus gain access to the contents within the interior space of a target storage container 9 in the stack. To alleviate this problem, the contents 6 of the storage container 9 can be placed on the exterior wall of the storage container 9 rather than on the inside of the storage container. This helps expose the contents of the storage container to allow access to the contents of the storage container from the side of the storage container. In the particular embodiment shown in FIG. 11(b), a shallow tray 8 is used to store one or more items 6, allowing easy access to the contents of the storage container 9 from the side of the storage container, thereby eliminating the need to lift the storage container to gain access to the open end of the storage container.

[0087] To stack multiple shallow trays 8 one on top of the other, in an exemplary embodiment of the present invention, a shallow tray 8 is mounted on legs or posts 8c to vertically space the shallow tray 8 above a vertically adjacent shallow tray 8 in the stack 11 in the grid framework structure 1. A stack of shallow trays 8 is shown in FIG. 7. As discussed above, the grid framework structure shown in FIG. 7 is an example of a grid framework structure of the first automated storage and retrieval system 52. FIG. 11(b) shows a perspective view in which a storage container 9 in the form of a shallow tray 8 is mounted on legs 8c such that the shallow tray 8 is elevated above a lower vertically adjacent storage container 9 in the stack 11, according to an exemplary embodiment of the present invention. As clearly shown in FIG. 7, each shallow tray 8 in the stack 11 is vertically spaced from the other trays in the stack by the shallow tray 8 being mounted on legs or posts 8c. Although each of the legs 8c extends along the longitudinal length of the shallow tray 8 as shown in FIG. 11(b), other means for vertically spacing the shallow trays 8 apart within the stack 11 are applicable to the present invention, as mounting the shallow trays 8 on the legs 8c is not required to vertically elevate the shallow trays 8. For example, the shallow trays 8 may form part of an outer or exterior wall of a box-like structure having opposing side and end walls. Using legs to vertically elevate the shallow trays helps to reduce the weight of the storage container. The legs 8c are configured to rest on a surface of the shallow tray 8 of a vertically adjacent storage container below in the stack 11 (see FIG. 7).

[0088] The upwardly extending rim 8b of the shallow tray acts as a barrier to prevent one or more items 6 in the shallow tray 8 from escaping the storage container 9. In a particular embodiment shown in FIG. 11(b), the upwardly extending rim 8b includes one or more cutouts 8d to allow easy access to the interior of the shallow tray 8 from the side. As shown in FIG. 11(b), the cutouts 8d in the rim of the shallow tray 8 are oriented such that the cutouts 8d of vertically adjacent storage containers in the stack 11 all face (or are aligned) in the same direction, in the sense that the interiors of the vertically adjacent shallow trays are exposed on one side of the stack, e.g., along a passageway in a grid framework structure. Even if any one of the load handling devices 31 becomes inoperative on the track system 13, access to the contents of the storage container 9 is still possible through the cutouts 8d in the rim of the shallow tray 8. Taking the example shown in FIG. 7, an operator can remove the contents 6 of the storage container 9 by proceeding along the passageway through which the contents of the storage container 9 are exposed.

[0089] To ensure that the item(s) 6 are prevented from falling out of the shallow tray 8 when the storage container is moved, the bottom wall 8e of the shallow tray 8 can be formed with a recess or a downwardly sloping bottom wall, so that the item(s) 6 resting on the bottom wall 8e are guided towards the recess under their own weight. In the particular example shown in Figure 11(b), the recess extends from an edge of the bottom wall 8e and is concave shaped. Although the particular embodiment shown in Figure 11(b) shows the storage container 9 as separate pieces, the shallow tray 8 and the storage container 9 with the upwardly extending rim 8b can be formed as a single integral body.

[0090] 11(a), a tilt mechanism 78 (not shown) tilts the smaller storage containers or trays 9 to a tilted position such that items on the smaller storage trays slide off the trays, through cutouts or openings in the rims of the trays, and onto a tilted platform or slide 80. One or more robotic arms 76 are configured to pick up the items from the slide 80 and place them in the larger storage containers 9 on the conveyor unit 62. The conveyor unit 62 transports the large storage containers 9 back to the grid framework structure of the second automated storage and retrieval system 52.

[0091] Figure 21 shows the pick station 64 of Figure 11 adjacent to the second automated storage and retrieval system 54. A storage container 9 is retrieved from the grid framework structure 1 of the second automated storage and retrieval system 54 by the load handling device 31 and transferred to the pick station 64 via a port column. The storage container 9 is within reach of the robotic arm 76 such that the robotic arm can pick an item from a slide 80 of the pick station 64 and place it directly into one of the larger storage containers 9.

[0092] As shown in FIG. 22, a plurality of pick stations 64 may be located adjacent to the grid framework structure 1 of the second automated storage and retrieval system 54 .

[0093] The transport system 56 is used to bring the large storage container 9 closer to the pick station 64 so that the storage container 9 is within reach of the robotic arm 76 .

[0094] FIG. 23 shows the location of the transport system 56 relative to the pick station 64. The pick station 64 is located below the grid framework structure 1 of the first automated storage and retrieval system 52. Only the gripping device of the robotic arm 76 at the pick station 64 can be seen to be below the grid framework structure 1. The transport system 56 (in this figure the transport system comprises the conveyor system 60) transports the large storage container 9 to a position adjacent to the pick station 64 so that the storage container 9 is within the reach of the robotic arm 76. As can be seen in FIG. 23, the port column 58 is positioned just above the transport system 56 so that the storage container can be lowered down the port column and onto the transport system. The storage container 9 can then be returned to the grid framework structure by being lifted up the port column and transported by the load handling device 31 to a position within the grid framework structure. To make optimal use of space and to transport items more efficiently, multiple transport systems can be placed in the corridor between the grid framework structures of the first and second automated storage and retrieval systems.

[0095] In an embodiment of the invention, a picking station can double up as a stock refill station. A picking / stock refill station has an access station that can function as both a picking station and / or a stock refill station. The picking station 64 is part of the first automated storage and retrieval system and cooperates with the second automated storage and retrieval system 52 to provide a system for retrieving one or more items from one or more storage containers 9 of the first automated storage and retrieval system and transferring them to the second automated storage and retrieval system. The picking station comprises one or more chutes forming a supply zone, an access station, and one or more bulk lifting devices forming a pick station buffer zone. The chutes and bulk lifting devices are examples of port columns 58. Referring to their name, the one or more chutes enable a load handling device 31 operable on the grid framework structure 1 to lower a storage bulk bin or container 9 without having any lifting assistance from the one or more chutes. This may be under the action of gravity, in which case the storage bin or container 9 is lowered down the chute under the weight of the storage bin or container 9 and / or whilst being lowered by the container lifting means 39 of the load handling device 31.

[0096] One or more items are picked from one or more storage bins or containers 9 in the access station depending on whether the access station functions as a pick station or an inventory replenishment station. One or more chutes and one or more bulk lifting devices are arranged to cooperate with the grid framework structure 1 described above. A plurality of grid cells 14 comprise drop-off ports (exit ports) and pick-up ports (entrance ports) arranged to cooperate with the one or more chutes and one or more bulk lifting devices, respectively. More specifically, the storage columns in which the drop-off ports and pick-up ports are located are arranged to cooperate with one or more chutes and one or more bulk lifting devices, respectively, of the picking station 64.

[0097] The picking station 64 of the present invention can be easily retrofitted to an existing grid framework structure 1 and can therefore be arranged as a stand-alone station that can cooperate with a track system extending overhead. For example, at least one chute and at least one bulk lifting device can be aligned with one or more storage columns 10 such that the storage containers or bulk containers 9 can easily pass through the storage columns 10 and into the at least one chute. Similarly, the storage bulk containers or containers 9 can be lifted from the at least one bulk lifting device and passed through the storage columns 10. The picking station 64 can be of modular construction, where the supply zone, the access station, and the pick station buffer zone can be formed as modules assembled together. As a result, the picking station 64 does not need to be connected to the grid framework structure 1, but can be formed as a separate part of the grid framework structure 1. The versatility of the picking station 64 being retrofitted to an existing grid framework structure 1 allows the picking station 64 to be assembled in various locations.

[0098] In one embodiment, the picking station 64 comprises a single framework that divides the picking station into a supply zone, a pick station buffer zone and an access station. The one or more chutes of the supply zone are receivable into the storage column 10 and comprise at least two vertical guides arranged to guide the storage bulk containers or containers 9 down the storage column 10 through the drop-off port and into the supply zone. For the sake of definition, the storage column 10 in which the drop-off port in the grid is located is called the delivery column. Similarly, the storage column 10 in which the pick-up port in the grid is located is called the pick-up column. In a particular embodiment of the invention, each of the one or more chutes comprises four guides that are receivable into the storage column of the grid framework structure 1. Each of the guides comprises two vertical plates (two mutually perpendicular container guide plates) that extend longitudinally along the length of the chute. One end of each of the guides is arranged to extend into the storage or delivery column and abuts against the four upright members that make up the storage column. Thus, a storage bulk container or container 9 lowered down the drop-off port is guided by guides through the distribution column (in which the drop-off port is located) and down a chute to the supply zone.

[0099] Side walls or panels are attached to the exterior of the at least two longitudinal guides to enclose the vertical chute. The side walls or paneling provide protection for an operator from one or more storage bins or containers descending down the chute into the feed zone. In one embodiment, a first portion of the guide is covered by the side walls or panels and a second portion of the guide is received within the delivery column. This allows the side walls or panels to provide a smooth transition from the delivery column to the chute of the pick station 64. [Direct transfer of a smaller container into a larger container] The present invention also encompasses embodiments in which a storage container from one automated storage and retrieval system may be placed directly inside a storage container from another automated storage and retrieval system, rather than items being picked from one storage container into another. Placing a storage container inside a storage container may be accomplished in a number of different ways. Some non-limiting examples are provided below, but it will be understood that any means of placing a storage container inside another storage container is within the scope of the present invention.

[0100] Small storage containers from the first automated storage and retrieval system 52 may be picked into larger storage containers from the second automated storage and retrieval system 54 by one or more robotic arms 76 in a similar manner as described above for picking individual items from small storage containers. The robotic arms may have suitable end effectors having gripping devices that engage features of the small storage containers, such as a rim or lip or aperture, or the robotic arms may grip opposing side walls of the small containers.

[0101] Alternatively, a flat surface may be placed on one or more conveyor units of a conveyor system and have one or more apertures in the flat surface such that the apertures are directly above the larger storage containers on the conveyor, thereby providing access to the larger storage containers through the apertures in the flat surface. The smaller storage containers may be lifted, dropped off, or slid into the larger container through the apertures in the flat surface. A robotic arm may be used to lift the smaller containers and place them through the apertures into the larger container. Alternatively, another conveyor unit at the same vertical height as the flat surface may be used to transport the smaller containers to the apertures so that they drop through the apertures into the larger container.

[0102] Another option is for the larger container to have an aperture in one of its side walls, or a side wall that can be removed, to provide access to the interior of the larger container. The smaller container can be slid into the larger container. A conveyor unit at the same vertical height as the base of the larger container may be used to transport the smaller container into the larger container. Alternatively, a slide or a downwardly inclined surface may be used to allow the smaller container to slide downwards into the larger container through an aperture in the side wall of the larger container, in a similar manner as described above with reference to FIG. 11(a). This method has the advantage that the smaller container is not subjected to a vertical drop, thus avoiding the risk of damage to the contents of the smaller container. [Automatic handling system] FIG. 12 shows another schematic view of an automated handling system 50 having a first and a second automated storage and retrieval system and a transfer system. The first automated storage and retrieval system 52 is adjacent to the second automated storage and retrieval system 54. The first automated storage and retrieval system is provided with port columns 58 on the opposite side to the second automated storage and retrieval system. These port columns 58 transport containers into the first automated storage and retrieval system 52 and are defined herein as pick-up port columns as described above. In the embodiment of the automated handling system 50 shown in FIG. 12, the grid framework structure 1 of the first automated storage and retrieval system 52 is divided into several subsections and the port columns 58 are separate from the main grid framework structure. The invention encompasses embodiments in which the grid framework structure 1 of any of the automated storage and retrieval systems is one structure or divided into subsections and in which the port columns 58 are integrated into the grid framework structure or are subsections thereof or are separate from the grid framework structure.

[0103] For example, in an application where the automated handling system 50 is a baggage handling system in an airport or other transportation hub, the items stored in the small containers of the first automated storage and retrieval system 52 may be passenger baggage or suitcases. After the passengers check in their baggage, the baggage may be transported (e.g., by one or more conveyors, not shown) to a receiving area adjacent to the first automated storage and retrieval system 52, and each suitcase or item of baggage may be placed in one of the small storage containers 9. The small storage containers 9 are then transferred into the first automated storage and retrieval system 52 by a port column 58. A load handling device 31 operable on the grid framework structure 1 of the first automated storage and retrieval system 52 retrieves the small storage container 9 containing the baggage and transports the container to one or more port columns 58, defined above as drop-off port columns herein, on the side of the first automated storage and retrieval system 52 adjacent to the second automated storage and retrieval system 54. The small containers 9 are transferred from the first automated storage and retrieval system 52 to one or more transfer systems 56 via port columns. The one or more transfer systems 56 comprise pick stations 64 that pick passenger baggage from the small containers of the first automated storage and retrieval system 52 and transfer them into large storage containers waiting in the transfer system, i.e. in the buffer zone. One large storage container can accommodate several suitcases or items of baggage allocated to the same means of transport (e.g. the same flight) or to the same destination. The large storage containers 9 are transported by the transfer system 56 to the second automated storage and retrieval system 54, where the large storage containers 9 are returned to the grid framework structure 1 of the second automated storage and retrieval system 54 via one or more port columns on the side of the second automated storage and retrieval system 54 adjacent to the transfer system 56.When baggage is needed, the large storage containers 9 are retrieved from the second automated storage and retrieval system 54 by a load handling device 31 operable on the grid framework structure of the second automated storage and retrieval system. The large storage containers 9 are transported by the load handling device to one or more port columns 58 on the side of the grid framework structure 1 opposite the side adjacent to the transport system. These port columns on the opposite side of the grid framework structure differ from the drop-off port columns and pick-up columns to and from the transport system 56 in that they provide secondary port columns for one or more storage containers to exit the grid framework structure. The large storage containers 9 are transported out of the second automated storage and retrieval system 54 via their respective port columns. The large storage containers 9 can then be loaded into the cargo hold of a passenger transport vehicle, such as an airplane or ship or train or other transport, so that the passenger's baggage can be transported to the appropriate destination.

[0104] FIG. 13 shows the automated handling system 50 of FIG. 12 in a schematic manner, where a platform 57 is below the upper layer of the section of the grid framework structure 1 of the first automated storage and retrieval system 52. The platform 57 provides an area for accommodating the port columns. FIG. 14 shows the automated handling system 50 of FIG. 13 in a schematic manner, where a single-layer grid framework structure 59 is above the platform 57. The single-layer grid framework structure 57 in this embodiment serves two purposes. First, the single-layer grid framework structure 59 allows the load handling device 31 to move between the port column 58 and the grid framework structure 1 of the first automated storage and retrieval system 52 in order to transport the storage containers from the port column to the grid framework structure. Second, the single-layer grid framework structure 59 allows the load handling device 31 to move between the different subsections of the grid framework structure 1 of the first automated storage and retrieval system 52 in order to transport the storage containers between the different subsections.

[0105] Figure 24 is a schematic diagram of the rear of the automated handling system of Figure 12. The figure shows cargo dollies 69 into which large storage containers 9 are loaded. Each cargo dolly 69 is positioned near one of the port columns 58 of the grid framework structure 1 of the second automated storage and retrieval system 54. The storage containers 9 are lowered downwardly through the port columns 58 and loaded into the cargo dollies 69.

[0106] The cargo dolly 69 may be positioned immediately below the port column 58 so that the storage containers 9 can be lowered directly onto the cargo dolly 69. Alternatively, the cargo dolly can be positioned adjacent to the port column 58 and a conveyor unit located at the bottom of the port column 58 can be used to transfer the storage containers from the port column 58 to the cargo dolly 69.

[0107] In applications where the automated handling system 50 is an automated baggage handling system, the large storage containers 9 are unit load devices (ULDs) and contain baggage items. After being loaded, a cargo dolly transports the ULDs to a passenger transport vehicle (e.g., an airplane, train, or ship) to be stowed in a cargo hold.

[0108] FIG. 25 is a schematic plan view of an automated handling system. Small storage containers 9 enter the automated handling system 50 through the port column 58 of the first automated storage and retrieval system 52. In FIG. 25, a row of storage containers can be seen lined by the port columns 58 waiting to enter the grid framework structure 1. After being stored in the grid framework structure 1 of the first automated storage and retrieval system 52, the small storage containers 9 are transported by the load handling device 31 to the port column 58 and down through the port column to the pick station 64. At the pick station 64, a robotic arm 76 picks items from the small storage containers into the transfer system 56, i.e., into the large storage containers waiting in the buffer zone. Once full, the large storage containers are brought by the transfer system to the port column 58 of the second automated storage and retrieval system 54. The large storage containers rise through the portal column 58 into the grid framework structure 1 of the second automated storage and retrieval system and are transported by the load handling device 31 to a location within the grid framework structure for storage. When larger storage containers are required, they are transported from the grid framework structure to the opposite portal column 58 and lowered down through the port column 58 and loaded onto the cargo dollies 69 . [Automated assembly line] Another application for the automated handling system 50 is an automated assembly system. In this application, the items stored in the first automated storage and retrieval system 52 are parts to be assembled and the items stored in the second automated storage and retrieval system 54 are assemblies of parts or final products. The transfer system comprises one or more assembly stations 65 (see Figures 19 and 20) where the parts are assembled. The parts may be assembled by workers and / or by robotic arms.

[0109] The storage containers are removed from the grid framework structure 1 of the first automated storage and retrieval system 52 by the load handling device 31 and taken to an assembly station 65 via one or more port columns. At the assembly station 65, the components from the smaller storage containers from the first automated storage and retrieval system 52 are assembled into an assembly or final product. The assembly or product is then placed in a larger storage container in the buffer zone 70. The large storage container containing the final product or assembly is then transported via a transfer system to a port column 58 of the second automated storage and retrieval system. The large storage container is transported up the port column 58 (pick-up port column) and transferred by one or more load handling devices 31 to a storage location in the second automated storage and retrieval system.

[0110] FIG. 19 shows an exemplary embodiment of an assembly station. A port column 58 transfers storage containers 9 from the first automated storage and retrieval system to an assembly station 65. The smaller storage containers contain the parts for assembly. FIG. 19 also shows racks 67 that may contain small parts or fittings (e.g., screws, nuts, bolts) required for assembly. In the embodiment shown in FIG. 19, assembly is performed by workers on trays located on a conveyor system. Each tray holds one assembly, and the trays may be advanced along the assembly line from one worker to the next in the line so that different workers can add different parts to the assembly. Once assembly is complete, the trays may be placed in a larger storage container (not depicted) ready to be sent by a transfer system to the second automated storage and retrieval system.

[0111] For example, if the automated assembly system is for assembling bicycles, the smaller storage containers contain the bicycle components (wheels, frame, gears, chain, brakes, saddle, handlebars, etc.) and the larger storage container is for storing the assembled bicycle. The first worker in the assembly line retrieves a bicycle frame from one small storage container and retrieves wheels from another small storage container. The worker assembles the bicycle wheels to the bicycle frame using bolts from rack 67 and places the assembled bicycle on an assembly tray. The assembly tray is then advanced along the assembly line to the next worker in the line, for example by a conveyor system. The next worker in the line accepts the assembly tray, takes a set of handlebars from another small storage container, and assembles the handlebars to the bicycle frame. The assembly tray advances to the next worker in the line who installs the gears to the bicycle frame. In this manner, the bicycle advances along the assembly line until all components are assembled. The finished bicycle is placed in a larger storage container and transported into the second automated storage and retrieval system.

[0112] FIG. 20 shows an automated assembly system incorporating the assembly station of FIG. 19. The automated assembly system comprises a first automated storage and retrieval system 52 and a second automated storage and retrieval system 54. The assembly station is located between the two automated storage and retrieval systems below the track system of the grid framework structure. Small load handling devices 31 of the first automated storage and retrieval system retrieve small storage containers from the grid framework structure and take them to a port column 58, which then lowers the storage containers down the port column to the assembly station. The components are assembled into products or assemblies at the assembly station, and the completed products or assemblies are then placed in large storage containers 9. The large storage containers are then transferred to the second automated storage and retrieval system by one or more port columns.

[0113] Although not depicted in FIG. 20, a conveyor may be used to transport the large storage containers 9 from the assembly station 65 to the port column 58 of the second automated storage and retrieval system so that the storage containers can be returned to the grid framework structure of the second automated storage and retrieval system. [Control System] In an exemplary embodiment of the invention shown in FIG. 15, the control system 82 coordinates the movement of one or more storage containers 9, or one or more items from a storage container, from the grid framework structure 1 of the first automated storage and retrieval system 52 for storage within the grid framework structure of the second automated storage and retrieval system 54. For ease and efficiency of explanation, the grid framework structure of the first automated storage and retrieval system 52 is referred to as "Grid A" and the grid framework structure of the second automated storage and retrieval system 54 is referred to as "Grid B". In accordance with the invention discussed above, Grid A does not coincide with Grid B, meaning that they store differently sized storage containers or totes. The intention is that multiple storage containers or the contents of multiple storage containers from Grid A may be aggregated or collated for storage in a single storage container from Grid B. In order to aggregate the contents of multiple storage containers from Grid A into a single storage container in Grid B, the storage containers in Grid A are smaller than the storage containers in Grid B. As a result, grid B is configured to accommodate larger storage containers by having larger grid openings 15 than grid openings 15 of grid A. FIG. 15 is a block diagram illustrating components of an automated handling system 50 according to an exemplary embodiment of the present invention. The control system 82 comprises one or more processors 84, memory 86 (e.g., read-only memory and random access memory), and a communication bus 88. The one or more processors 84 of the control system 82 may execute instructions stored in ROM and / or RAM to provide at least part of the functionality of the automated load handling system described herein. The one or more processors 84 of the control system 82 are communicatively coupled to a wireless / wired transceiver (not shown) via the communication bus 88. A cloud (not shown) may form part of the control system such that data processing and storage may be performed within the cloud.The control system 82 is instructed to execute instructions operable to receive a request for the transfer or shipment of one or more items or goods and generate a unique identification 92(a and b) for the request that is communicated to a user's personal communication device via a wired / wireless network. The unique identification 92(a and b) comprises data associated with the user. The data can be represented as a tier system where the data associated with the user can represent a tier 1 identification and depending on the application of the automated load handling system of the present invention, the data can include other attributes associated with the user, e.g., flight data as a tier 2 identification in case the automated load handling system is an automated baggage handling system. The tier system allows the control system to identify and aggregate storage containers in grid A based on certain attributes of the unique identification. This can be tier 1 data and / or lower level data associated with the user, e.g., flight data in case one or more storage containers of a particular flight are aggregated together for transfer to a single storage container in grid B. Following a request to aggregate one or more storage containers in grid A based on a particular attribute of their respective unique identities, the control system identifies relevant storage containers in grid A based on the particular attribute of their respective unique identities, which may be associated with a user specification or lower in the tier system.

[0114] Although the automated load handling device is applicable to any application requiring collation or consolidation of items, to facilitate description of the control system's functionality for coordinating the movement of one or more storage containers for consolidation into a single storage container, the automated load handling system will be described with respect to an automated baggage handling system. In the case of an automated baggage handling system, the user may include a passenger and the unique identification comprises data associated with user-defined destinations and / or travel data, e.g., flight details.

[0115] Referring to the flow diagram shown in FIG. 16 in conjunction with FIG. 15, a process 100 of allocating unique identities 92(a and b) to storage containers in a grid framework structure begins with one or more users requesting to hold one or more items for transport to a user-defined destination in step 102. In the case of an automated baggage handling system, the one or more items can be one or more pieces of baggage or luggage items. In the check-in disc, the control system generates a label or baggage identification tag 90a in step 104 with a unique identification 92 associated with the user as a tier 1 identification and the associated user-defined destination together with other travel data as a tier 2 identification, etc. The label 90a with the unique identification can be encoded in a barcode, 1D barcode, 2D barcode, or QR code or RFID tag. The label 90a is readable by a user interface 93a to establish the identity of the stored luggage. The baggage or luggage is then deposited in a storage container for subsequent transfer to Grid A where it is stored before being aggregated into a larger storage container in Grid B. A similar process of generating unique identifications 92b comprising data associated with specific attributes of storage containers held in Grid B is applicable in the present invention. The relationship between the unique identifications 92(a and b) between storage containers held in Grid A and storage containers held in Grid B is discussed further below and depends on the specific application of the automated baggage handling system. For example, the relationship may be travel data if the automated load handling system is an automated baggage handling system.

[0116] To locate the storage container for a particular user, the control system 82 assigns the generated unique identification to the storage container held within grid A in step 106. The process of assigning the generated unique identification to the storage container within grid A may include assigning the unique identification associated with the user to a grid location of the storage container within grid A. The grid location may be represented by a Cartesian coordinate system X, Y, Z. For purposes of the present invention, the track system 13 guides the movement of the robotic load handling device 31 in the X and Y directions in a horizontal plane above the track system 13, and the lifting mechanism 39 is configured to move the gripping device 43 in a third Z direction to access the lower storage container 9 in the stack 11. For purposes of the present application, Z=1 defines the top layer of the grid framework structure 1, i.e., the layer immediately below the track system 13, Z=2 is the second layer below the track system 13, Z=3 is the third layer below the track system 13, and so on. The location of each of the storage containers 9 held within the grid framework structure 1 of the first and second storage and retrieval systems (Grids A and B) 52, 54 may be represented by a Cartesian coordinate system X, Y, Z. For example, the storage containers may be said to be located within a grid location determined from the Cartesian coordinate system X, Y, Z. The unique identification 92a may include data associated with the user as a Tier 1 identification, travel data as a Tier 2 identification, and the grid location of the storage container associated with the user as a Tier 3 identification.

[0117] Movement of the storage containers to and from their respective grid locations within grid A is performed by one or more robotic load handling devices 96a operable on the track system 13 of grid A. Typically, the one or more load handling devices 96a operable remotely on the grid framework structure are configured to receive instructions from a master controller to retrieve a storage container 9 from a particular storage location within the grid framework structure. The master controller may form part of the control system 82 discussed with reference to FIG. 15. Wireless communications and networks may be used to provide a communications infrastructure from the master controller via one or more base stations to one or more load handling devices operable on the grid framework structure. In response to receiving the instructions, the controllers in the robotic load handling devices are configured to control various drive mechanisms to control the movement of the load handling devices. For example, the load handling devices may be instructed to retrieve a storage container 9 from a storage column 10 at a particular location on the grid framework structure. The storage column 10 has particular X, Y coordinates in a Cartesian coordinate system, and the depth of the storage column 10 may be represented by a Z coordinate. The instructions may include various movements in the XY directions on the grid framework structure. Upon reaching the storage column 10, the lifting mechanism 39 operating in the Z direction then grasps the storage container 9 and lifts it into a container receiving space in the body 33 of the load handling device 31, where it is transported to another location on the grid framework structure, commonly known as a drop-off port, where it is lowered in a port column 58. The instructions include movements of the storage container 9 to and from that grid location to at least one port column 58 of grid A where the storage container 9 can be dropped off.Once a user has checked their baggage at the check-in disk, the baggage associated with the user has been assigned a unique identification 92a, and the baggage has been placed in a storage container 9, the storage container 9 is moved by a load handling device 31 operable on the track system 13 to a grid location in grid A. This may be a dedicated grid location assigned by the control system 82, or a grid location selected by the user at the check-in disk. The grid location of the storage container in grid A is assigned the unique identification 92a associated with the user as discussed above. This process is repeated for various users at the check-in disk.

[0118] As a result, the allocation and movement of storage containers for storage in grid A and the assignment of unique identities to grid locations of storage containers in grid A are automated processes that occur in the background or back office away from the users. This is compared to the need to manually remove baggage from a conveyor onto a loading station for subsequent transfer to a ULD as currently practiced in the art. In the present invention, the high storage density of the grid framework structure according to the present invention allows multiple baggage items from various users to be transferred to grid A for sorting where they are subsequently transferred to a storage container in grid B. Operation of multiple automated storage and retrieval systems, each of which comprises a grid framework structure 1 and multiple load handling devices 31 operable on the grid framework structure to move storage containers from their grid locations to a port column, allows the storage containers held in one grid framework structure to be sorted and / or relocated for transfer to a storage container in another grid framework structure. Assigning unique identifications 92(a and b) to storage containers in step 106 aids in sorting and / or consolidating one or more items from one grid framework structure for transfer to a storage container in another grid framework structure.

[0119] The unique identifications 92a for the various users may be stored in a database 94a (hereafter referred to as the "Grid A database" in FIG. 15) in step 108. The database is communicatively coupled to the control system 82. As shown in FIG. 15, the Grid A database 94a in communication with the control system 82 includes information associated with the users (passengers). This information may include the unique identification associated with the user, and / or the amount of remaining space available in a designated storage container, and / or the size / dimensions / volume / weight of the baggage, and / or the grid location of the storage container within Grid A, or other relevant information within the tier system. The unique identifications 92a identifying each storage container may be included on a label 90a affixed to the storage container such that the storage container may be identified by scanning the label with an input device 93a (see FIG. 15). The input device 93a may include, but is not limited to, a radio frequency identification reader, a linear and / or matrix bar code reader, or an infrared reader. The database may store associations between baggage items, for example, which baggage items belong to the same user or the same shipment. The storage containers are held in Grid A until they require transfer to one or more larger storage containers in Grid B for aggregation.

[0120] A similar database 94b is provided in communication with the control system 82 for storage of information associated with storage containers held in Grid B of the second automated storage and retrieval system 54. The storage containers held in Grid B are of a different size than the storage containers in Grid A and are intended to store items or storage containers aggregated and transferred from Grid A to Grid B. Similar to the unique identification 92a associated with one or more users in Grid A, the unique information 92b comprises data associated with the storage containers held in Grid B and may comprise information regarding the grid location of the storage container in Grid B, the amount of remaining space available in a specified storage container, and / or the size / dimensions / volume / weight of the storage container, and / or the grid location of the storage container in Grid B, or other relevant information within the tier system. Similar to the storage containers held in Grid A, the unique identification 92b associated with the storage containers held in Grid B may be identified by a label or tag 90b affixed to the storage container. An input device 93b in the transport system 56, for example in the buffer zone 70, can identify a storage container from grid B from the label or tag 90b.

[0121] In the case of an automated baggage handling system, the storage containers in grid B can be unit load devices (ULDs) used to load luggage or cargo loads into vehicles, such as aircraft, trains, or ships. Similar to the grid locations of the storage containers in grid A, the grid locations of the storage containers in grid B can be represented by a Cartesian coordinate system, X, Y, Z. The difference between grid A and grid B is the size of the respective grid framework structures, where the grid openings 15 in grid A are smaller than the grid openings 15 in grid B. Similar to grid A of the first automated storage and retrieval system 52, one or more load handling devices 31 operable on the track system 13 of grid B are instructed to move one or more storage containers 9 to and from their respective grid locations for drop-off at port columns 58 in grid B. The instructions include movement of the storage containers 9 to and from their respective grid locations to at least one port column 58 of grid B. As discussed above, the load handling device includes a wheel assembly for movement in the X and Y directions on the track system 13 and a gripping device 43 for gripping the storage container 9 from its grid location and placing it into a container receiving space of the load handling device 31.

[0122] The exemplary embodiment of FIG. 15 shows two databases 94, one 94a for storing data associated with a unique identification 92a of a storage container from grid A and the other 94b for storing data associated with a unique identification 92b of a storage container from grid B, such that data from both unique identifications 92(a and b) can be stored in a single database 94.

[0123] An exemplary embodiment of selecting a storage container from Grid A for aggregation in a particular storage container in Grid B having unique identification 92(a and b) in step 110 may be described with reference to the flow diagram of FIG. 17. For ease of explanation, the term "unique identification" has been abbreviated to "UI" and the load handling device has been abbreviated to "bot" in FIG. 17. The process begins in steps 112, 114 with the control system 82 commanding a load handling device 31 operable on the track system 13 of Grid B to locate and retrieve a storage container 9 from its grid location to a drop-off port where it is then lowered through at least one port column 58 and transported by at least one transport system 56 to the buffer zone 70. The request 112 to retrieve a storage container from Grid B may depend on the need to aggregate items from Grid A into a storage container from Grid B.

[0124] The movement of the storage containers by the at least one transport system 56 from the at least one port column 58 discussed above involves one or more conveyor units 62. The buffer zone 70 represents a portion of the at least one transport system 56, where one or more storage containers 9 from grid B are held while one or more items or storage containers from grid A are loaded. In the buffer zone 70, the identity of the storage container is determined by determining the unique identification 92b of the storage container using an input device 93b in step 116. The input device 93b can be a scanner, such as a barcode scanner, a QR code reader, or other input device for determining the unique identification 92b of the storage container. The input of the unique identification 92b into the control system 82 can be by manual operation, such as a handheld scanner, or automatic operation, such as an attached scanner. After the identity of the storage containers is determined from their respective unique identifications, the control system determines and locates the storage containers held in grid A having the corresponding unique identification 92a in step 118. The correspondence between the unique identities of the storage containers in Grid A and Grid B is based on the application of the automated load handling system of the present invention. In the case of the example automated baggage handling system, the correspondence between the unique identities between the storage containers from Grid B and Grid A may be travel details, e.g., flight number, or a user defined destination. The label of the storage container from Grid B may include data associated with the flight details, destination, etc. The control system 82 may search a database of unique identities associated with the user to identify any corresponding flight details stored with the unique identities 92(a and b) that may be held in the tier system, e.g., tier 2 identification.

[0125] The control system 82 identifies one or more storage containers in grid A having a unique identification 92a that corresponds to the unique identification 92b of a storage container from grid B in the buffer zone 70. Once identified, the control system 82 instructs one or more load handling devices 31 operable on the track system 13 of grid A to pick the identified storage container 9 and move the storage container down at least one port column 58 to be dropped off at the pick station 64 in step 122. At the pick station 64, one or more items from the various storage containers from grid A are transferred in step 124 to the storage containers in the buffer zone 70 where they are aggregated in the storage containers in the buffer zone 70. In the case of an automated baggage handling system, the one or more items can be baggage and the storage containers in the buffer zone can be unit load devices (ULDs). Baggage or baggage from the various storage containers in the pick station are transferred to the ULDs in the buffer zone. The control system 82 ensures that the unique identification 92a of the storage container containing the baggage from grid A corresponds to the unique identification 92b of the ULD in the buffer zone 70, e.g., flight details and destination. Automating the allocation of baggage from grid A for transfer to a ULD in grid B eliminates human error resulting in misplaced baggage being loaded onto the wrong ULD. An input device 93a at the pick station 64 ensures that the unique identification 92a of the storage container corresponds to the unique identification 92b of the storage container in the buffer zone 70 to prevent the wrong item from being loaded into the storage container in the buffer zone, thus providing a fail-safe mechanism.

[0126] The transfer of one or more items from a storage container at the pick station 64 to a storage container at the buffer zone 70 can be a manual operation. However, to increase the automation of the automated load handling system 50 of the present invention, picking items from the storage container 9 at the pick station 64 where they are transferred for consolidation in a storage container at the buffer zone 70 can be automated using a robotic arm 76 that can grab items from the storage container and transfer them to a storage container at the buffer zone as shown in FIG. 10. Although the exemplary embodiment describes picking one or more items to be transferred to a storage container at the buffer zone 70, the storage container deposited at the pick station 64 can itself be transferred for loading into a storage container at the buffer zone. Similarly, it is also applicable in the present invention that the storage container 9 can comprise an outer storage container and an inner storage container, otherwise known as a shipping container. The shipping container from one or more storage containers at the pick station 64 can be transferred to a larger storage container at the buffer zone 70. After one or more items (baggage) from one or more storage containers are aggregated in a storage container in the buffer zone, the storage container in the buffer zone is moved to at least one port column 58 of grid B where it can then be picked up by a load handling device 31 operable on the track system 13 of grid B and transported to a grid location of grid B where the storage container can then be stored for later use. In the case of an automated baggage handling system, the ULD held in grid B is then removed by a load handling device 31 operable on the track system 13 of grid B when it is required to be loaded onto a vehicle, for example into an aircraft cargo hold.When requested to be loaded onto the aircraft cargo hold, the control system 82 can instruct the robotic load handling device 31 operable on the track system 13 of grid B to pick the ULD based on its associated unique identification 92b and deposit the ULD in at least one port column 58 where the ULD can be loaded onto a cargo dolly suitable for transport to the aircraft cargo hold.

[0127] However, if there is no storage container that can be identified from Grid A with a corresponding unique identification, the control system requests another storage container from Grid B. The absence of a storage container from Grid A with a corresponding unique identification may be due to a delay in the allocation of the storage container within its respective grid in Grid A. Alternatively, in this scenario, the storage container from Grid B can optionally be removed from the grid and held in an intermediate holding facility 71 in the buffer zone 70 until a storage container from Grid A is allocated.

[0128] While the exemplary embodiment of the flow chart of FIG. 17 begins with the control system 82 instructing the load handling device 31 to remove a storage container from grid B before identifying a container in grid A by its corresponding unique identification 92, the opposite is applicable, i.e., the control system identifies a storage container from grid B by the corresponding unique identification of one or more storage containers in a port column from grid A.

[0129] Similarly, it is also possible in the present invention that the at least one transfer system 56 can comprise at least one conveyor unit 62 for directly transferring one or more storage containers from at least one port column 58 of grid A to at least one port column 58 of grid B. Although the exemplary embodiment of FIG. 17 illustrates the automated load handling system 50 as an automated baggage handling system, the automated load handling system 50 of the present invention can be used in other applications requiring sorting and / or matching of items. The use of at least two automated storage and retrieval systems 52, 54, each comprising the grid framework structure 1 described above, allows for sorting and matching or consolidating one or more items from one storage container to another larger storage container.

[0130] An advantage of using an automated load handling system 50 having a first and second automated storage and retrieval system 52, 54 and at least one transport system 56 linking them to collate or aggregate one or more items is that the automated load handling system 50 of the present invention can also find application in an assembly line in a manufacturing process. For example, items from the first automated storage and retrieval system 52 can be aggregated and assembled into a product that can form part of a machine, e.g., a pump, a motor, or an entire product, e.g., a bicycle, a washing machine, etc. Thus, instead of the unique identification 92(a and b) comprising data associated with one or more users as discussed above, the unique identification 92(a and b) can comprise data associated with at least a portion of a product or an entire product in an assembly line, such that a product is created when the items are assembled together. In other words, one or more items can be considered to represent one or more components of at least a portion of a product in an assembly line. As a result, the unique identification 92(a and b) comprises data associated with the product or at least a portion of a product. One or more items from one or more storage containers 9 may be aggregated or matched together based on their respective unique identities 92(a and b) associated with at least a portion of the product to be assembled at the assembly station 65. As a result, the at least one transport system 56 may further comprise an assembly station 65 for assembling one or more items or components removed from grid A before the assembled product is transferred to grid B.

[0131] The unique identification 92a of the storage container in Grid A may be associated with at least a portion of the product or products assembled at the assembly station 65. Thus, the database 94a for Grid A comprises data associated with the unique identifications 92(a and b) that identify the product or at least a portion of the product assembled at the assembly station as a Tier 1 identification and its corresponding grid location as a Tier 2 identification. The assembled product may then be transferred to a storage container 9 in the buffer zone 70 for subsequent storage in Grid B. The storage container 9 in Grid B has a unique identification 92b that corresponds to the unique identification of the product assembled at the assembly station 65. As discussed above, the database 94b for Grid B comprises data associated with the assembled product and its grid location in Grid B. The operations of labeling the items and / or storage containers with information related to their respective unique identifications 92 and inputting the unique identifications 92 into the control system 82 via the input device are as described above.

[0132] FIG. 18 illustrates exemplary steps of a process for assembling at least a portion of a product 130 using an automated load handling system 50 according to the present invention. In a first step 132, a request is made to assemble the product at the assembly station 65. The control system 82 determines the components or items required to assemble the product at the assembly station 65. This involves determining a unique identification 92a of a storage container containing the items from grid A in step 134. As discussed above, the unique identification 92 is associated with the product to be assembled at the assembly station 65. The unique identification 92 comprises data associated with the grid location of the storage container 9 containing the respective assembled item. After all of the items or components have been identified, the control system 82 instructs one or more load handling devices 31 operable on the track system 13 of grid A to retrieve the storage container 9 containing the respective item in step 136. The load handling device 31 transports the storage container 9 to at least one port column 58 of grid A, where the storage container 9 is then transferred to at least one transfer system 56. Labels with unique identification 92 information from storage containers 9 on at least one transport system 56 are scanned and entered into control system 82. Control system 82 determines in step 138 whether all of the components or items on assembly station 65 are present to assemble the product. If not, control system 82 then commands one or more load handling devices 31 to identify the missing items or components and remove them from grid A. If all of the items are present, then the items are aggregated for assembly at assembly station 65 in step 140.

[0133] As with pick station 64 described above, assembly of items can be manual or automated. For example, automated operation can involve one or more robotic arms 76 performing automated assembly steps such as welding, fastening, positioning, etc. Products assembled at assembly station 65 are then transferred to grid B for storage. Control system 82 can be instructed to retrieve one or more storage containers 9 having unique identities corresponding to the products assembled at assembly station and move one or more storage containers 9 to buffer zone 70 in step 122. The assembled products are transferred to the storage containers 9 in buffer zone 70 in step 124. Transfer can also involve scanning a label on a storage container 9 in buffer zone 70 and inputting information from the label into control system 82. The information on the label includes the unique identification of the storage container in buffer zone 70, which is then stored in database 94b (grid B database). Unique identification 92b is a record of the assembled products stored in grid B and their respective grid locations. A load handling device 31 operable on a track system 13 of Grid B transports the storage container 9 from the buffer zone 70 to a grid location in Grid B. The grid location is assigned to the unique identification 92b of the storage container in Grid B. This process of assembling one or more items from Grid A, assembling at an assembly station 65, and storing the assembled product in Grid B is repeated for other items in Grid A. Thus, Grid A provides the components of the product to be assembled and Grid B provides the storage of the assembled product. At least one transport system 56 linking Grid A and Grid B to each other provides the stations necessary to link Grid A to Grid B.

[0134] An advantage of the automated load handling system 50 according to the present invention is that the process of sorting and / or matching or consolidating one or more items can be automated. Bottlenecks resulting from manual sorting and / or consolidation of one or more items can be automated making the sorting and / or consolidation process an even faster process. Multiple transport systems 56 can act in parallel to sort and / or match one or more items having different unique identities 92, e.g., different flight details in the case of an automated baggage handling system, from a first automated storage and retrieval system 52 to a second automated storage and retrieval system 54. Furthermore, using a grid framework structure 1 to hold storage containers 9 allows for a higher density of storage containers to be held for a given footprint of the storage facility. [Definition] It is contemplated that any one or more of the variations described within the preceding sections may be implemented in the same embodiment of an automated handling system.

[0135] In this document, the term "movement in the n-direction," where n is one of x, y, and z (and related phrases), is intended to mean movement substantially along or parallel to the n-axis in both directions (i.e., toward the positive end of the n-axis or toward the negative end of the n-axis).

[0136] In this document, the word "connect" and its derivatives are intended to include the possibilities of direct and indirect connection. For example, "x is connected to y" is intended to include the possibilities of x being directly connected to y without an intervening component, and the possibilities of x being indirectly connected to y with one or more intervening components. Where a direct connection is intended, the words "directly connected", "direct connection", or similar will be used. Similarly, the term "support" and its derivatives are intended to include the possibilities of direct and indirect contact. For example, "x supports y" is intended to include the possibilities of x supporting y directly without an intervening component, directly contacting y, and the possibilities of x supporting y with one or more intervening components contacting x and / or y. The word "attach" and its derivatives are intended to include the possibilities of direct and indirect attachment. For example, "x is mounted on y" is intended to include the possibility that x is directly mounted on y with no intervening components, and the possibility that x is indirectly mounted on y with one or more intervening components.

[0137] In this document, the word "comprises" and its derivatives are intended to have an inclusive rather than exclusive meaning. For example, "x comprises y" is intended to include the possibility that x contains only one y, multiple y, or one or more y and one or more other elements. When an exclusive meaning is intended, the words "x consists of y" are used, which means that x does not contain anything other than y.

[0138] In this document, a "controller" is intended to include any hardware suitable for controlling (e.g., providing instructions to) one or more components, such as a processor equipped with one or more memories and suitable software for processing data associated with the component or components and sending appropriate instructions to the components to enable them to perform their / their intended function. The following is a summary of the claims as originally filed: [1] An automated load handling system comprising: A) first and second automated storage and retrieval systems; and B) at least one port column, A) each of the first and second automated storage and retrieval systems comprises: i) a grid framework structure; and ii) a plurality of robotic load handling devices; i) the grid framework structure, a) a track system comprising a first set of parallel tracks and a second set of parallel tracks extending transversely to the first set in a substantially horizontal plane, the track system being arranged in a grid pattern comprising a plurality of grid cells, each grid cell defining a grid opening defined by a pair of adjacent tracks of the first set of parallel tracks and a pair of adjacent tracks of the second set of parallel tracks; b) a plurality of storage columns, each arranged to store a respective stack of storage containers for storing one or more items, the stacks of storage containers positioned below the track system such that each stack of storage containers occupies a single grid space or grid cell; Equipped with ii) the robotic load handling device is operable on the track system to lift and move one or more storage containers from a stack; B) the one port column extends downwardly from a grid opening of the track system of each of the first and second automated storage and retrieval systems, through which a respective robotic load handling device operable on the track system can drop off and pick up one or more storage containers; 1. An automated load handling system, comprising: C) at least one transfer system configured to transfer one or more storage containers or one or more items from the storage containers from the at least one port column of the first automated storage and retrieval system to the at least one port column of the second automated storage and retrieval system; 11. The automated load handling system of claim 10, wherein the grid openings of the track system of the first automated storage and retrieval system are sized differently than the grid openings of the track system of the second automated storage and retrieval system such that the grid framework structure of the first automated storage and retrieval system is configured to store storage containers that are sized differently than the storage containers stored in the grid framework structure of the second automated storage and retrieval system. [2] The automated load handling system of [1], wherein the grid opening of the track system of the first automated storage and retrieval system is smaller than the grid opening of the track system of the second automated storage and retrieval system such that the grid framework structure of the first automated storage and retrieval system is configured to store storage containers that are smaller than the storage containers stored within the grid framework structure of the second automated storage and retrieval system. [3] The automated load handling system of [1] or [2], wherein the at least one port column of each of the grid framework structures of the first and second automated storage and retrieval systems comprises an entrance port column for accepting one or more storage containers transferred from the at least one transport system, and an exit port column for dropping off one or more storage containers to the at least one transport system. [4] The automated load handling system of [3], wherein the at least one transfer system comprises at least one conveyor system having at least one conveyor unit extending from an exit port column of the grid framework structure of the first or second automated storage and retrieval system to an entrance port column of the grid framework structure of the first or second automated storage and retrieval system for transporting one or more storage containers into and out of a respective grid framework structure of the automated storage and retrieval system. [5] The automated load handling system of any one of [1] to [4], wherein the at least one transfer system comprises at least one conveyor system having at least one conveyor unit extending from the at least one port column of the grid framework structure of the first automated storage and retrieval system to the at least one port column of the grid framework structure of the second automated storage and retrieval system for transporting one or more storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system. [6] The automated load handling system of [3], wherein the at least one transfer system comprises at least one conveyor system comprising a first conveyor system arranged to transport one or more storage containers into and out of the grid framework structure of the first automated storage and retrieval system, and a second conveyor system arranged to transport one or more storage containers into and out of the grid framework structure of the second automated storage and retrieval system. [7] The automated load handling system of any one of [4] to [6], wherein the at least one conveyor system comprises an entrance conveyor unit, an exit conveyor unit, and a transfer conveyor unit, the exit conveyor unit arranged to transport storage containers in a first direction from the exit port column to the transfer conveyor unit, and the entrance conveyor unit arranged to transport storage containers in a second direction from the transfer conveyor unit to the entrance port column. [8] The automated load handling system of [7], wherein the transfer conveyor unit is configured to transport storage containers in a third direction. [9] The automated load handling system of [8], wherein the exit conveyor unit and the entrance conveyor unit are arranged such that the first direction of the exit conveyor unit is opposite to and parallel to the second direction of the entrance conveyor unit, and the third direction of the transfer conveyor unit is substantially perpendicular to both the first direction of the exit conveyor unit and the second direction of the entrance conveyor unit.

[10] The automated load handling system of any one of [7] to [9], wherein the at least one transfer system is provided with a buffer zone for holding one or more storage containers in the transfer conveyor units of the first and / or second automated storage and retrieval systems.

[11] The automated load handling system of

[10] , wherein the at least one transport system includes a pick station for receiving storage containers dropped off from the at least one port column of the grid framework structure of the first automated storage and retrieval system.

[12] The automated load handling system of

[11] , wherein the pick station comprises a robotic arm for transferring one or more items from one or more storage containers from the first automated storage and retrieval system to one or more storage containers on the transfer conveyor unit of the second automated storage and retrieval system.

[13] The automated load handling system of

[11] or

[12] , wherein the pick station comprises a tilting mechanism for tilting the storage container and a slide adjacent to the tilting mechanism for capturing one or more items that exit the tilting mechanism.

[14] An automated load handling system as described in any one of [1] to

[13] , wherein the storage containers of the first automated storage and retrieval system comprise shallow trays mounted on spacing means so as to be vertically spaced from one another within the stack within the grid framework structure of the first automated storage and retrieval system.

[15] The automated load handling system of

[14] , wherein each of the shallow trays comprises a bottom wall and an upwardly extending rim having one or more cutouts through which one or more items inside the shallow trays can be accessed when the shallow trays are stored in a stack within the grid framework structure of the first automated storage and retrieval system.

[16] The automated load handling system of any one of [1] to

[15] , wherein the at least one transfer system comprises at least one assembly station for assembling one or more items from one or more storage containers from the first automated storage and retrieval system.

[17] The automated load handling system of any one of [1] to

[16] , wherein each of the plurality of load handling devices of the first and second automated storage and retrieval systems comprises a lifting mechanism comprising a gripping device configured to releasably engage a storage container and a winch mechanism configured to lift the storage container above the track system.

[18] The present invention further comprises a control system comprising one or more processors and a memory storing instructions that, when executed by the one or more processors, a) receiving a request for storage of an item associated with at least a portion of a user or product; b) generating a unique identification comprising data associated with the user or the at least a portion of the product; c) assigning said unique identification to a storage container within said first automated storage and retrieval system; d) The automated load handling system of any one of [1] to

[17] , configured to store data associated with the unique identification in a database.

[19] The automated load handling system of

[18] , wherein the unique identification is assigned to a storage container within the first automated storage and retrieval system by correlating the grid location of the storage container within the grid framework structure of the first automated storage and retrieval system to the unique identification.

[20] The control system, a) generating a unique identification comprising data associated with each storage container within the second automated storage and retrieval system; b) The automated load handling system of

[18] or

[19] , further configured to assign the unique identification of the storage container to a grid location of the storage container within the grid framework structure of the second automated storage and retrieval system.

[21] The automated load handling system of

[20] , wherein the control system is configured to aggregate or collate a plurality of items from one or more storage containers in the first automated storage and retrieval system based on their respective unique identifications for transfer to a storage container in the grid framework structure of the second automated storage and retrieval system.

[22] The automated load handling system of

[21] , wherein the control system is configured to aggregate or match the items from one or more storage containers in the first automated storage and retrieval system by aggregating their respective unique identities associated with at least a portion of one or more users or products.

[23] The automated load handling system of

[22] , wherein the control system is configured to assign the aggregated unique identification associated with at least a portion of one or more users or products to a unique identification of the storage container of the second automated storage and retrieval system.

[24] the control system, based on the corresponding unique identification of the storage container of the second automated storage and retrieval system on the at least one transfer system, i) correlating the unique identities associated with one or more users with the corresponding unique identities of the storage containers of the second automated storage and retrieval system in the at least one transport system; ii) locating the one or more storage containers within the grid framework structure of the first automated storage and retrieval system based on correlating the unique identification to the grid location of the storage container within the grid framework structure of the first automated storage and retrieval system; iii) commanding one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers from the grid locations and move the one or more storage containers to the at least one port column of the first automated storage and retrieval system;

[23] The automated load handling system of

[23] , further configured to instruct one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve one or more storage containers.

[25] The automated load handling system of any one of

[18] to

[24] , wherein each of the one or more items stored in the one or more storage containers in the first automated storage and retrieval system is a baggage item, the unique identification associated with the user is baggage tag data, the baggage tag data comprising data associated with a user specified destination together with reservation data indicative of travel destination, and each of the one or more storage containers in the second automated storage and retrieval system is a unit load device (ULD).

[26] The automated load handling system of any one of

[21] to

[23] , wherein at least a portion of the products comprise an assembly of the aggregated or collated multiple items.

[27] The control system, based on a unique identification associated with the at least a portion of the product, i) identifying one or more storage containers comprising one or more items each forming a part of said at least a portion of said product; ii) locating the one or more storage containers within the grid framework structure of the first automated storage and retrieval system based on correlating the unique identification to the grid location of the storage container within the grid framework structure of the first automated storage and retrieval system; iii) by commanding one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers, each of which comprises one or more items for assembly into at least a portion of the product, from its grid location and move the one or more storage containers to the at least one port column of the first automated storage and retrieval system;

[26] The automated load handling system of

[26] , further configured to instruct one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers to respective port columns of the first automated storage and retrieval system.

[28] A method of handling one or more items within an automated load handling system according to any one of

[18] to

[25] in response to one or more storage containers from a second automated storage and retrieval system on at least one transport system, comprising: i) identifying one or more storage containers comprising one or more items by correlating unique identities associated with one or more users from a first automated storage and retrieval system with unique identities of the one or more storage containers from the second automated storage and retrieval system in the at least one transport system; ii) instructing one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more identified storage containers and move the one or more storage containers to at least one port of a grid framework structure of the first automated storage and retrieval system; iii) transferring one or more items from the identified one or more storage containers to the one or more storage containers from the second automated storage and retrieval system on the at least one transfer system; iv) instructing one or more load handling devices operable on the track system of the second automated storage and retrieval system to move the one or more storage containers from the at least one transport system to storage columns of the grid framework structure of the second automated storage and retrieval system; A method for providing the above.

[29] The method of

[28] , further comprising the step of instructing one or more load handling devices operable on the track system of the second automated storage and retrieval system to retrieve one or more containers from the grid framework structure of the second automated storage and retrieval system to the at least one transport system based on the unique identification of the one or more identified storage containers from the first automated storage and handling system.

[30] A method of assembling one or more items from the automated load handling system of

[26] or

[27] to form at least a part of a product, comprising the steps of: i) identifying one or more storage containers from a first automated storage and retrieval system that include one or more items having a unique identification associated with the at least some of the products; ii) commanding one or more load handling devices operable on a track system of the first automated storage and retrieval system to retrieve one or more storage containers, each storage container comprising one or more items for assembly into the at least a portion of the product, from its grid location and move the one or more storage containers to the at least one port column of the first automated storage and retrieval system; iii) assembling the one or more items from the one or more storage containers to form the at least a portion of the product; iv) transferring said at least a portion of said products to said one or more storage containers from said second automated storage and retrieval system on said at least one transfer system; v) instructing one or more load handling devices operable on the track system of the second automated storage and retrieval system to move the one or more storage containers from the at least one transport system to storage columns of a grid framework structure of the second automated storage and retrieval system; The method comprises:

Claims

1. 1. An automated load handling system comprising: A) first and second automated storage and retrieval systems; and B) at least one port column, A) each of the first and second automated storage and retrieval systems comprises: i) a grid framework structure; and ii) a plurality of robotic load handling devices; i) the grid framework structure comprises: a) a track system comprising a first set of parallel tracks and a second set of parallel tracks extending transversely to the first set in a substantially horizontal plane, the track system being arranged in a grid pattern comprising a plurality of grid cells, each grid cell defining a grid opening defined by a pair of adjacent tracks of the first set of parallel tracks and a pair of adjacent tracks of the second set of parallel tracks; b) a plurality of storage columns, each arranged to store a respective stack of storage containers for storing one or more items, the stacks of storage containers positioned below the track system such that each stack of storage containers occupies a single grid space or grid cell; Equipped with ii) the robotic load handling device is operable on the track system to lift and move one or more storage containers from a stack; B) the one port column extends downwardly from a grid opening of the track system of each of the first and second automated storage and retrieval systems, through which a respective robotic load handling device operable on the track system can drop off and pick up one or more storage containers; 1. An automated load handling system, comprising: C) at least one transfer system configured to transfer one or more storage containers or one or more items from said storage containers from said at least one port column of said first automated storage and retrieval system to said at least one port column of said second automated storage and retrieval system; 11. The automated load handling system of claim 10, wherein the grid openings of the track system of the first automated storage and retrieval system are a different size than the grid openings of the track system of the second automated storage and retrieval system such that the grid framework structure of the first automated storage and retrieval system is configured to store storage containers that are sized differently than the storage containers stored in the grid framework structure of the second automated storage and retrieval system.

2. 2. The automated load handling system of claim 1, wherein the grid openings of the track system of the first automated storage and retrieval system are smaller than the grid openings of the track system of the second automated storage and retrieval system such that the grid framework structure of the first automated storage and retrieval system is configured to store storage containers that are smaller than the storage containers stored within the grid framework structure of the second automated storage and retrieval system.

3. 3. The automated load handling system of claim 1 or 2, wherein the at least one port column of each of the grid framework structures of the first and second automated storage and retrieval systems comprises an entrance port column for accepting one or more storage containers transferred from the at least one transport system and an exit port column for dropping off one or more storage containers to the at least one transport system.

4. 4. The automated load handling system of claim 3, wherein the at least one transfer system comprises at least one conveyor system comprising at least one conveyor unit extending from the exit port column of the grid framework structure of the first or second automated storage and retrieval system to the entrance port column of the grid framework structure of the first or second automated storage and retrieval system for transporting one or more storage containers into and out of a respective grid framework structure of the automated storage and retrieval system.

5. 3. The automated load handling system of claim 1 or 2, wherein the at least one transfer system comprises at least one conveyor system comprising at least one conveyor unit extending from the at least one port column of the grid framework structure of the first automated storage and retrieval system to the at least one port column of the grid framework structure of the second automated storage and retrieval system for transporting one or more storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system.

6. 4. The automated load handling system of claim 3, wherein the at least one transfer system comprises at least one conveyor system comprising: a first conveyor system arranged to transport one or more storage containers into and out of the grid framework structure of the first automated storage and retrieval system; and a second conveyor system arranged to transport one or more storage containers into and out of the grid framework structure of the second automated storage and retrieval system.

7. 5. The automated load handling system of claim 4, wherein the at least one conveyor system comprises an entrance conveyor unit, an exit conveyor unit, and a transfer conveyor unit, the exit conveyor unit arranged to transport storage containers in a first direction from the exit port column to the transfer conveyor unit, and the entrance conveyor unit arranged to transport storage containers in a second direction from the transfer conveyor unit to the entrance port column.

8. The automated load handling system of claim 7 , wherein the transfer conveyor unit is arranged to transport storage containers in a third direction.

9. 9. The automated load handling system of claim 8, wherein the exit conveyor unit and the entrance conveyor unit are arranged such that the first direction of the exit conveyor unit is opposite to and parallel to the second direction of the entrance conveyor unit, and the third direction of the transfer conveyor unit is substantially perpendicular to both the first direction of the exit conveyor unit and the second direction of the entrance conveyor unit.

10. 8. The automated load handling system of claim 7, wherein the at least one transfer system comprises a buffer zone for holding one or more storage containers in the transfer conveyor units of the first and / or second automated storage and retrieval systems.

11. 11. The automated load handling system of claim 10, wherein the at least one transport system comprises a pick station for receiving storage containers dropped off from the at least one port column of the grid framework structure of the first automated storage and retrieval system.

12. 12. The automated load handling system of claim 11, wherein the pick station comprises a robotic arm for transferring one or more items from one or more storage containers from the first automated storage and retrieval system to one or more storage containers on the transfer conveyor unit of the second automated storage and retrieval system.

13. 12. The automated load handling system of claim 11, wherein the pick station comprises a tilt mechanism for tilting the storage container and a slide adjacent to the tilt mechanism for capturing one or more items exiting the tilt mechanism.

14. 3. The automated load handling system of claim 1 or 2, wherein the storage containers of the first automated storage and retrieval system comprise shallow trays mounted on spacing means so as to be vertically spaced from one another within the stack within the grid framework structure of the first automated storage and retrieval system.

15. 15. The automated load handling system of claim 14, wherein each of the shallow trays comprises a bottom wall and an upwardly extending rim with one or more cutouts through which one or more items inside the shallow tray can be accessed when the shallow tray is stored in a stack within the grid framework structure of the first automated storage and retrieval system.

16. 3. The automated load handling system of claim 1 or 2, wherein the at least one transfer system comprises at least one assembly station for assembling one or more items from one or more storage containers from the first automated storage and retrieval system.

17. 3. The automated load handling system of claim 1 or 2, wherein each of the plurality of load handling devices of the first and second automated storage and retrieval systems comprises a lifting mechanism comprising a gripping device configured to releasably engage a storage container and a winch mechanism configured to lift the storage container above the track system.

18. and a control system comprising one or more processors and a memory storing instructions that, when executed by the one or more processors, a) receiving a request for storage of an item associated with at least a portion of a user or product; b) generating a unique identification comprising data associated with the user or the at least a portion of the product; c) assigning said unique identification to a storage container within said first automated storage and retrieval system; 3. The automated load handling system of claim 1 or 2, configured to: d) store data associated with said unique identification in a database.

19. 20. The automated load handling system of claim 18, wherein the unique identification is assigned to a storage container in the first automated storage and retrieval system by correlating the grid location of the storage container within the grid framework structure of the first automated storage and retrieval system to the unique identification.

20. The control system comprises: a) generating a unique identification comprising data associated with each storage container within the second automated storage and retrieval system; 20. The automated load handling system of claim 18, further configured to: b) assign the unique identification of the storage container to a grid location of the storage container within the grid framework structure of the second automated storage and retrieval system.

21. 21. The automated load handling system of claim 20, wherein the control system is configured to aggregate or collate a plurality of items from one or more storage containers in the first automated storage and retrieval system based on their respective unique identifications for transfer to a storage container in the grid framework structure of the second automated storage and retrieval system.

22. 22. The automated load handling system of claim 21, wherein the control system is configured to aggregate or match the items from one or more storage containers in the first automated storage and retrieval system by aggregating their respective unique identities associated with at least a portion of one or more users or products.

23. 23. The automated load handling system of claim 22, wherein the control system is configured to assign the aggregated unique identities associated with at least a portion of one or more users or products to unique identities of the storage containers of the second automated storage and retrieval system.

24. the control system, based on a corresponding unique identification of the storage container of the second automated storage and retrieval system on the at least one transport system, i) correlating the unique identities associated with one or more users with the corresponding unique identities of the storage containers of the second automated storage and retrieval system in the at least one transport system; ii) locating the one or more storage containers within the grid framework structure of the first automated storage and retrieval system based on correlating the unique identification to the grid location of the storage container within the grid framework structure of the first automated storage and retrieval system; iii) by commanding one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers from the grid locations and move the one or more storage containers to the at least one port column of the first automated storage and retrieval system; 24. The automated load handling system of claim 23, further configured to instruct one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve one or more storage containers.

25. 20. The automated load handling system of claim 18, wherein each of the one or more items stored in the one or more storage containers in the first automated storage and retrieval system is a baggage item, the unique identification associated with the user is baggage tag data, the baggage tag data comprises data associated with a user specified destination together with reservation data indicative of travel data, and each of the one or more storage containers in the second automated storage and retrieval system is a unit load device (ULD).

26. 22. The automated load handling system of claim 21, wherein at least a portion of the products comprise an assembly of the aggregated or collated items.

27. the control system, based on a unique identification associated with the at least a portion of the product, i) identifying one or more storage containers comprising one or more items each forming a part of said at least a portion of said product; ii) locating the one or more storage containers within the grid framework structure of the first automated storage and retrieval system based on correlating the unique identification to the grid location of the storage container within the grid framework structure of the first automated storage and retrieval system; iii) by instructing one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers, each of which comprises one or more items for assembly into at least a portion of the product, from its grid location and move the one or more storage containers to the at least one port column of the first automated storage and retrieval system; 27. The automated load handling system of claim 26, further configured to instruct one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers to respective port columns of the first automated storage and retrieval system.

28. 20. A method of handling one or more items in an automated load handling system according to claim 18 in response to one or more storage containers from a second automated storage and retrieval system on at least one transport system, comprising: i) identifying one or more storage containers comprising one or more items by correlating unique identities associated with one or more users from a first automated storage and retrieval system with unique identities of the one or more storage containers from the second automated storage and retrieval system in the at least one transport system; ii) instructing one or more load handling devices operable on the track system of the first automated storage and retrieval system to retrieve the one or more identified storage containers and move the one or more storage containers to at least one port of a grid framework structure of the first automated storage and retrieval system; iii) transferring one or more items from the identified one or more storage containers to the one or more storage containers from the second automated storage and retrieval system on the at least one transport system; iv) instructing one or more load handling devices operable on the track system of the second automated storage and retrieval system to move the one or more storage containers from the at least one transport system to storage columns of the grid framework structure of the second automated storage and retrieval system; A method for providing the above.

29. 30. The method of claim 28, further comprising the step of instructing one or more load handling devices operable on the track system of the second automated storage and retrieval system to retrieve one or more containers from the grid framework structure of the second automated storage and retrieval system to the at least one transport system based on the unique identification of the one or more identified storage containers from the first automated storage and handling system.

30. 27. A method of assembling one or more items from the automated load handling system of claim 26 to form at least a portion of a product, comprising the steps of: i) identifying one or more storage containers from a first automated storage and retrieval system that include one or more items having a unique identification associated with the at least some of the products; ii) instructing one or more load handling devices operable on a track system of the first automated storage and retrieval system to retrieve one or more storage containers, each of which comprises one or more items for assembly into the at least a portion of the product, from its grid location and move the one or more storage containers to the at least one port column of the first automated storage and retrieval system; iii) assembling the one or more items from the one or more storage containers to form the at least a portion of the product; iv) transferring said at least a portion of said products to said one or more storage containers from said second automated storage and retrieval system on said at least one transfer system; v) instructing one or more load handling devices operable on the track system of the second automated storage and retrieval system to move the one or more storage containers from the at least one transport system to storage columns of a grid framework structure of the second automated storage and retrieval system; A method comprising:

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