Storage System

Abstract

The present invention provides a storage system comprising: a storage grid structure in which storage containers are stored; and a plurality of container handling vehicles, the storage grid structure having an outline of vertical columns interconnected at their upper ends by upper rails forming a horizontal upper rail grid along which the container handling vehicles can move in two orthogonal directions; the container handling vehicles are capable of retrieving storage containers from the storage grid structure, storing the storage containers therein, and transporting the storage containers on the upper rail grid; the storage system being characterised in that it comprises at least one integrated vehicle; a transfer rail grid; an item picking area; and an item delivery station.

Description

[Technical field]

[0001] The present invention relates to an automated storage and retrieval system and a method for the use of an automated storage and retrieval system. [Background technology]

[0002] Figures 1A and 2B disclose a typical prior art automated storage and retrieval system 1 with a framework structure 100. Figures 1B and 2B disclose prior art container handling vehicles 200, 300, respectively, operating in the system 1 disclosed in Figures 1A and 2A.

[0003] The framework structure 100 defines a storage grid 104 comprising a plurality of upright members 102 and, optionally, a plurality of horizontal members 103 that support the upright members 102. The members 102, 103 may typically be made from metal, for example, extruded aluminum sections.

[0004] The storage grid 104 comprises a number of grid columns 112. Most of the grid columns are also referred to as storage columns 105, in which storage containers 106, also known as bins, are stacked on top of each other to form stacks 107.

[0005] Each storage container 106 will typically hold multiple product items (not shown), and the product items within the storage containers 106 may be the same or may be different product types, depending on the application.

[0006] The storage grid 104 protects the storage containers 106 from horizontal movement in the stack 107 and guides the vertical movement of the containers 106, but does not typically otherwise support the storage containers 106 when stacked.

[0007] The automated storage and retrieval system 1 comprises a rail system 108 (or upper rail grid) arranged in a grid pattern across the top of the storage grid 104, on which a plurality of container handling vehicles 200, 300 (as illustrated in Figures 1B and 2B) are operated to raise storage containers 106 from, lower storage containers 106 into, and transport storage containers 106 above the storage columns 105. The horizontal extent of one of the grid cells 122 of the grid pattern is marked by a bold line in Figures 1A and 2A.

[0008] Each grid cell 122 has a width that is typically in the interval of 30-150 cm, and a length that is typically in the interval of 50-200 cm. Each grid opening 115 typically has a width and length that is 2-10 cm less than the width and length of the grid cell 122 due to the horizontal extent of the rails 110, 111.

[0009] The rail system 108, also referred to as the upper rail grid, comprises a first set 110 of parallel rails arranged to guide the movement of the container handling vehicles 200, 300 in a first direction X across the top of the framework structure 100, and a second set 111 of parallel rails arranged perpendicular to the first set 110 of rails to guide the movement of the container handling vehicles 200, 300 in a second direction Y that is perpendicular to the first direction X. The rail system 108 thus defines the upper end of a grid column 112 above which the container handling vehicles 200, 300 may move laterally, i.e. in a plane that is parallel to the horizontal XY plane. Typically, at least one of the rail sets 110, 111 is constructed of a dual track rail, allowing two container handling vehicles to pass each other on neighboring grid cells 122. Dual track rails are well known and are disclosed, for example, in WO2015 / 193278A1 and WO2015 / 140216A1, the contents of which are incorporated herein by reference.

[0010] A schematic diagram of a grid cell 122 as defined when both sets of rails in a rail system are dual track rails is shown in Figure 3. On such a rail system, a container handling vehicle 200 having a maximum perimeter that fits within the lateral area defined by a grid cell 122 is allowed to travel along a row of grid columns even if another container handling vehicle 200 is positioned above a neighboring grid column in that row. Each grid cell 122 comprises a grid opening 115 bounded by a pair of rails 110a, 110b of a first set 110 of parallel rails and a pair of rails 111a, 111b of a second set 111 of parallel rails. In Figure 3, the grid cells 122 are indicated by dashed box.

[0011] As a result, rails 110a and 110b form a neighboring rail pair that defines a parallel row of grid cells extending in the X direction, and rails 111a and 111b form a neighboring rail pair that defines a parallel row of grid cells extending in the Y direction.

[0012] Each prior art container handling vehicle 200, 300 comprises a vehicle body and a wheel arrangement of eight wheels, with a first set of four wheels 32a allowing lateral movement of the container handling vehicle 200, 300 in the X direction and a second set of four wheels 32b allowing lateral movement in the Y direction. One or both sets of wheels in the wheel arrangement can be raised and lowered so that the first set of wheels and / or the second set of wheels can be engaged with the respective set of rails 110, 111 at any time.

[0013] Each prior art container handling vehicle 200, 300 also includes a lifting device 34 (shown only in FIG. 2B ) for vertical transportation of the storage containers 106 (e.g., raising the storage containers 106 from and lowering them into grid columns). The lifting device 34 includes four metal lifting bands 31 that extend in orthogonal directions and are connected proximate the corners of the lifting frame 33 (which may also be referred to as a gripping device) so that the lifting frame remains horizontal. The lifting frame 33 features container connection elements 35 and guide pins 30 for releasable connection to the storage containers 106.

[0014] Conventionally, and for purposes of this application, Z=1 identifies the topmost layer of the grid 104, i.e., the layer immediately below the rail system 108, Z=2 identifies the second layer below the rail system 108, Z=3 identifies the third layer, and so on. In the prior art storage grid disclosed in Figures 1A and 2A, Z=8 identifies the bottom, lowermost layer of the grid 104. As a result, using, by way of example, the Cartesian coordinate system X, Y, Z shown in Figures 1A and 2B, a storage container identified as 106' in Figure 1 can be considered to occupy grid location or cell X=10, Y=2, Z=3. The container handling vehicles 200, 300 can be considered to be traveling at layer Z=0, and each grid column can be identified by its X and Y coordinates.

[0015] Each container handling vehicle 200 includes a storage compartment or space (not shown) for receiving and storing the storage containers 106 as they are transported across the top of the storage grid 104. The storage space may include a centrally located cavity within the vehicle body, for example, as described in WO 2014 / 090684 A1, the contents of which are incorporated herein by reference.

[0016] Alternatively, the container handling vehicle 300 may have a cantilever beam structure as described in No. 317366, the contents of which are also incorporated herein by reference.

[0017] The container handling vehicle 200 may have a footprint, i.e., extent in the X and Y directions, that is generally equal to the horizontal area of ​​the grid cell 122, i.e., the extent of the grid cell 122 in the X and Y directions, as described, for example, in WO2015 / 193278A1, the contents of which are incorporated herein by reference.

[0018] Alternatively, the container handling vehicle 200 may have a footprint larger than the horizontal area of ​​a grid cell 122, for example as disclosed in WO2014 / 090684A1.

[0019] In the storage grid 104, the majority of the grid columns 112 are storage columns 105, i.e., grid columns in which the storage containers 106 are stored in the stacks 107. However, the grid 104 does have at least one grid column 112 that is not normally used to store the storage containers 106, but is located at a location where a container handling vehicle 200, 300 may unload and / or load the storage containers 106 so that they can be transported to a second location (not shown) where they can be accessed from outside the grid 104 or transferred in and out of the grid 104. In the art, such locations are normally referred to as "ports" and the grid columns in which the ports are located may be referred to as transfer columns 119, 120. The unloading and loading ports are the tops / openings of the respective transfer columns 119, 120.

[0020] The prior art storage grid 104 of Figures 1A and 2A comprises two transfer columns 119 and 120. The first transfer column 119 may comprise a dedicated unloading port where, for example, the container handling vehicles 200, 300 may unload storage containers 106 to be further transported, for example, to a picking / stocking station through the transfer column 119, and the second transfer column 120 may comprise a dedicated loading port where, for example, the container handling vehicles 200, 300 may load storage containers 106 transported, for example, from the picking / stocking station through the transfer column 120. The storage containers may be transported through the transfer columns by use of the lifting devices of the container handling vehicles 200, 300 or by use of storage container lifts arranged in the transfer columns. Each of the ports of the first and second transfer columns may be suitable for both loading and unloading of storage containers.

[0021] The second location may typically be a picking / stocking station where product items are removed from and / or placed into storage containers 106. At the picking / stocking station, the storage containers 106 are typically never removed from the automated storage and retrieval system 1, but are placed back into the storage grid 104 once accessed.

[0022] To monitor and control the automated storage and retrieval system 1 (e.g., to monitor and control the location of each storage container 106 within the storage grid 104, the contents of each storage container 106, and the movements of the container handling vehicles 200, 300 so that the desired storage containers 106 may be delivered to the desired locations at the desired times without the container handling vehicles 200, 300 colliding with each other), the automated storage and retrieval system 1 typically includes a computerized control system (not shown) that includes a database for tracking the storage containers 106.

[0023] A conveyor system comprising conveyor belts or rollers is typically employed to transport the storage containers from the lower ends of the transfer columns 119, 120 to, for example, a picking / stocking station.

[0024] The conveyor system may also be arranged to transport storage containers between different storage grids, for example as described in WO2014 / 075937A1, the contents of which are incorporated herein by reference.

[0025] Furthermore, WO2016 / 198467A1 (the contents of which are incorporated herein by reference) discloses examples of prior art access systems having conveyor belts (Figures 5a and 5b in WO2016 / 198467A1) and frame-mounted rails (Figures 6a and 6b in WO2016 / 198467A1) for transporting storage containers between a transfer column and a station where an operator may access the storage containers.

[0026] When a storage container 106 stored within the storage grid 104 disclosed in FIG. 1A is to be accessed, one of the container handling vehicles 200, 300 is commanded to retrieve the target storage container 106 from its position within the grid 104 and transport it to or through the transfer column 119. This operation involves moving the container handling vehicle 200, 300 to a grid location above the storage column 105 where the target storage container 106 is located, retrieving the storage container 106 from the storage column 105 using a lifting device (not shown) on the container handling vehicle, and transporting the storage container 106 to the transfer column 119. If the target storage container 106 is located deep within the stack 107, i.e., with one or more other storage containers positioned above the target storage container 106, the operation also involves temporarily moving the upper positioned storage container prior to lifting the target storage container 106 from the storage column 105. This step, sometimes referred to in the art as "digging," may be performed using the same container handling vehicle 200, 300 that is subsequently used to transport the target storage container 106 to the transfer column, or using one or more other cooperating container handling vehicles 200, 300. Alternatively, or in addition, the automated storage and retrieval system 1 may have a container handling vehicle 200, 300 that is specifically dedicated to the task of temporarily removing a storage container 106 from a storage column 105. Once the target storage container 106 is removed from the storage column 105, the temporarily removed storage container can be repositioned in the original storage column 105. However, the removed storage container may alternatively be relocated to another storage column 105.

[0027] When a storage container 106 is to be stored in a grid 104, one of the container handling vehicles 200, 300 is commanded to load the storage container 106 from the transfer column 120 and transport it to the grid location above the storage column 105 where it is to be stored. After any storage containers located at or above the target location in the storage column stack 107 are removed, the container handling vehicles 200, 300 position the storage container 106 in the desired location. The removed storage container can then be lowered back into the storage column 105 or relocated to another storage column 105.

[0028] A common operation performed in prior art storage systems is the consolidation of different items loaded from the storage grid, for example, items belonging to a single customer order, which are consolidated for further processing, such as packaging in a single package for shipment to the customer.

[0029] In prior art systems, consolidation of multiple items is performed by first transferring a storage container containing the items in the order from a storage grid to a manual picking / stocking station. At the picking / stocking station, an operator loads the required items of the order and places them in a single package for further processing, e.g., shipping to a customer. The different items to be consolidated are usually stored in different storage containers, and the speed of the consolidation process is therefore limited by the rate at which different storage containers are made available at the picking / stocking station. Furthermore, due to the continuous access to different storage containers, identical orders with the same items from the same storage container are processed less quickly than non-identical orders, since the storage container must be cycled between the picking / stocking station and the storage grid for each order.

[0030] The efficiency of the consolidation process of the prior art is not optimal for several other reasons. Both the picking / stocking station and the area required for consolidation of items must be located adjacent to each other so that the operator can easily transfer the items between the picking / supply station and the packaging in which the items are consolidated. The picking stations of the prior art are located on the periphery of the storage grid, and the positioning of both the picking / supply station and the area required for consolidation of items, e.g., the conveyor belt for the transport of packaging for the consolidated items, is set. The set positioning can be disadvantageous when the storage system has to be adapted to a given building layout. Alternatively, the area required for consolidation of items, e.g., the conveyor belt for the transport of packaging for the consolidated items, can be located in a separate location, but this would significantly reduce the efficiency of the consolidation process.

[0031] In view of the above, it is an object of the present invention to provide a storage system, and a method for operating such a system, that overcomes, or at least mitigates, one or more of the aforementioned problems associated with the use of prior art storage systems.

[0032] It is an object of the present invention to provide a storage system which is more effective than prior art systems in consolidating items to be stowed from the storage system.

[0033] Another object is to provide a more flexible storage system. [Prior art documents] [Patent documents]

[0034] [Patent Document 1] International Application Publication No. 2015 / 193278 [Patent Document 2] International Application Publication No. 2015 / 140216 Summary of the Invention [Means for solving the problem]

[0035] The invention is defined by the appended claims and below. In a first aspect, the present invention provides a storage system comprising a storage grid structure in which storage containers are stored and a plurality of container handling vehicles, the storage grid structure comprising vertical column profiles interconnected at their upper ends by a top rail forming a horizontal top rail grid along which the container handling vehicles may move in two orthogonal directions, the container handling vehicles being capable of retrieving storage containers from the storage grid structure, storing the storage containers therein and transporting the storage containers on the top rail grid, the storage system comprising at least one integrated vehicle, a transfer rail grid, an item picking area and an item delivery station;

[0036] - the integrated vehicle comprises a wheel arrangement for moving the integrated vehicle in two orthogonal directions on the transfer rail grid;

[0037] the transfer rail grid comprises transfer rails along which the integrated vehicles may move in two orthogonal horizontal directions;

[0038] the item picking area comprising a first section of a transfer rail grid at which an integrated vehicle may be positioned to receive a plurality of items loaded from at least one storage container, and an item picker arranged to load the items from the storage container and transfer them to the integrated vehicle;

[0039] the item delivery station comprises a second section of the transport rail grid on which the integrated vehicle can be positioned to deliver the items received from the storage container to the packaging / processing assembly;

[0040] The integrated vehicle is equipped with an item carrier arranged such that items can be transferred from the item carrier when the integrated vehicle is positioned at the item delivery station.

[0041] In other words, the item carrier is positioned such that when the integrated vehicle is positioned at the item delivery station, items may be transferred from the item carrier without the involvement of an operator or any external device such as a robotic arm. In other words, the integrated vehicle comprises an item carrier positioned such that when the integrated vehicle is positioned at the item delivery station, the integrated vehicle may transfer items from the item carrier. Alternatively, the item carrier may be defined as comprising an item transfer assembly positioned to move items contained by the item carrier in a lateral or downward direction such that when the integrated vehicle is positioned at the item delivery station, the items may be transferred from the item carrier.

[0042] In an embodiment of the storage system, an integrated vehicle may be positioned on the first section to receive a plurality of items loaded from a plurality of storage containers.

[0043] In one embodiment of the storage system, the item carrier has an open top and the item carrier includes an openable section arranged such that items may be removed from the item carrier when the openable section is open.

[0044] In an embodiment of the storage system, the openable section may be connected to at least one actuator arranged to move the section between an open position and a closed position. In the closed position, items may not be transferred out of the item carrier. In other words, the openable section is arranged such that when the openable section is in the open position, items contained within the item carrier may be transferred out of the item carrier.

[0045] In some embodiments of the storage system, the item carrier is an integral part of the integrated vehicle.

[0046] In one embodiment of the storage system, the item carriers are positioned to support packaging boxes into which items can be received at the item picking area.

[0047] The item carrier may comprise a space in which an item may be placed.

[0048] In some embodiments, the storage system comprises a plurality of integrated vehicles.

[0049] In one embodiment, the storage system includes at least a first integrated vehicle and a second integrated vehicle.

[0050] In some embodiments, a storage system may include multiple item picking areas.

[0051] In an embodiment, the storage system may comprise at least first and second item picking areas. The first and second item picking areas may comprise separate sections of a transport rail grid.

[0052] In an embodiment, the storage system may include first and second storage grid structures. The transfer rail grid may be arranged such that an integrated vehicle may be positioned in a picking area and receive loaded items from storage containers that are placed in or retrieved from either of the first and second storage grid structures.

[0053] In one embodiment, the storage system may include a first item picking area where the integrated vehicle may retrieve loaded items from a storage container located or retrieved from within a first storage grid, and a second item picking area where the integrated vehicle may retrieve loaded items from a storage container located or retrieved from within a second storage grid.

[0054] In some embodiments, the storage system may include multiple item delivery stations.

[0055] In certain embodiments of the storage system, the upper rail grid is separate from the transfer rail grid. In other words, the upper rail grid and the transfer rail grid are separate such that container handling vehicles are prevented from entering the transfer rail grid and integration vehicles and optionally container transfer vehicles (see below) are prevented from entering the upper rail grid. The upper rail grid and the transfer rail grid can be separate by being located at different levels or separate in the horizontal plane by having a blocking element, e.g. a fence, located between the two grids or by being located at a distance from each other.

[0056] In one embodiment of the storage system, the transport rail grid is disposed at a level lower than the level of the upper rail grid.

[0057] In one embodiment of the storage system, the transport rail grid is disposed at a level below the level of the upper rail grid.

[0058] In one embodiment of the storage system, the item carrier comprises a peripheral sidewall and a bottom section, and the openable section constitutes a section of the peripheral sidewall or the bottom section. The peripheral sidewall and the bottom section define a space in which items may be placed.

[0059] In certain embodiments of the storage system, items contained within the item carrier may be transferred from the item carrier in a lateral or downward direction when the integrated vehicle is positioned at the item delivery station.

[0060] In an embodiment of the storage system, the wheel arrangement may comprise first and second sets of wheels, one or both sets of wheels may be connected to a wheel lifting mechanism and may be raised and lowered such that the first set of wheels and / or the second set of wheels may be engaged with a respective set of transport rails of the transport rail grid at any one time. The wheel arrangement is motorized such that the integrated vehicle may be driven in two orthogonal directions on the transport rail grid.

[0061] In one embodiment of the storage system, the item picker comprises a robotic arm, or in other words, the item picker may be a robotic picking arm.

[0062] The robotic picking arm may be movable in a horizontal direction at a level above the level of the transfer rail grid such that an integrated vehicle may be positioned below the robotic picking arm. The robotic picking arm may be movable along a horizontal beam. The beam may be supported by a column such that at least a portion of the beam is disposed above the transfer rail grid and allows access for the integrated vehicle below the beam and the robotic picking arm. The robotic picking arm may be positioned such that at least one item may be loaded from any of the multiple storage containers. Each of the multiple storage containers may be disposed at an upper level of a corresponding storage column or may be housed within a container transfer vehicle disposed in a first section of the transfer grid.

[0063] In one embodiment of the storage system, the integrated vehicle comprises an actuator connected to an openable section of the peripheral sidewall or bottom section, the actuator being arranged to move the section of the sidewall or the section of the bottom section between an open position and a closed position.

[0064] In one embodiment of the storage system, items contained within an item carrier of an integrated vehicle can be transferred out of the item carrier when the integrated vehicle is positioned at an item delivery station and an openable section of a side wall or bottom section is in an open position.

[0065] In some embodiments of the storage system, the openable section of the peripheral sidewall or bottom section comprises a hinged surface.

[0066] In one embodiment of the storage system, the integrated vehicle includes an openable section of a peripheral sidewall and a conveyor belt at a bottom section of the item carrier, the peripheral sidewall extending above an upper level of the conveyor belt, the peripheral sidewall preventing items placed within the item carrier from exiting the item carrier until the openable section of the peripheral sidewall is open.

[0067] In one embodiment of the storage system, an openable section of the side wall is hinged at the upper section of the item carrier such that a lower end of the openable section is raised when in the open position.

[0068] In one embodiment of the storage system, the item delivery station includes an opening or conveyor positioned to guide items transferred from the consolidated vehicle to the packaging / processing assembly.

[0069] The conveyor can be any suitable type of conveyor, such as a roller or belt conveyor. In an embodiment, the conveyor is a belt conveyor for accommodating items of any size suitable for storage in a storage container. The belt conveyor can be arranged to guide and transport the items in a lateral direction.

[0070] The openings may be located below the second section of the transport rail grid, preferably at a level below a grid cell of the second section of the transport rail.

[0071] The opening may be located above a packaging / processing assembly, such as a conveyor featuring packaging boxes or containers to which items from the at least one integrated vehicle can be guided, or above a suitable conveyor for guiding items to the packaging / processing assembly.

[0072] In one embodiment of the storage system, the transfer rail is a dual track rail so that two integrated vehicles can pass each other on adjacent grid cells of the transfer rail grid.

[0073] In one embodiment of the storage system, the integrated vehicles have a horizontal perimeter that fits within the horizontal area defined by the grid cells of the transport rail grid, i.e., the maximum horizontal perimeter.

[0074] In one embodiment of the storage system, the vertical column configuration defines a plurality of storage columns, the storage containers are stored one on top of the other in a vertical stack, and a container handling vehicle is capable of retrieving the storage containers from the storage columns and storing the storage containers therein.

[0075] In one embodiment of the storage system, the vertical column configuration defines at least one transfer column along which a container handling vehicle may transfer storage containers between the upper rail grid and a lower level of the storage grid structure.

[0076] In an embodiment, the storage system comprises at least one container transfer vehicle having a storage container carrier and a wheel arrangement arranged to move the container transfer vehicle in two orthogonal directions on a transfer rail grid with a third section arranged below the transfer column of the storage grid such that a container handling vehicle can raise or lower the storage container between the storage container carrier and the upper rail grid. The wheel arrangement may comprise eight wheels, a first set of four wheels allowing lateral movement of the container transfer vehicle in a first direction and a second set of the remaining four wheels allowing lateral movement in a second direction perpendicular to the first direction. One or both sets of wheels in the wheel arrangement may be connected to a wheel lifting mechanism and may be raised and lowered such that the first set of wheels and / or the second set of wheels may be engaged with the respective set of transfer rails of the transfer rail grid at any one time.

[0077] In one embodiment of the storage system, the wheel arrangement of the consolidation vehicle is the same as the wheel arrangement of the container transfer vehicle.

[0078] In one embodiment of the storage system, the container transfer vehicle has a horizontal perimeter that fits within the horizontal area defined by the grid cells of the transfer rail grid, i.e., the maximum horizontal perimeter.

[0079] In some embodiments of the storage system, the consolidation vehicle may be equipped with a weighing mechanism to measure the weight of the items contained by the item carrier. The measured weight may be used to optimize the consolidation process.

[0080] In a second aspect, the present invention provides an integrated vehicle for a storage system according to the first aspect, the integrated vehicle comprising a wheel arrangement and an item carrier,

[0081] the wheel arrangement is for moving the integrated vehicle in two orthogonal directions on a transfer rail grid;

[0082] - the item carrier comprises a peripheral side wall, a bottom section and an open top, the section of the peripheral side wall being openable so that items may be transferred from the item carrier in a lateral direction.

[0083] In some embodiments, the item carrier may be box-shaped.

[0084] In one embodiment of the integrated vehicle, the wheel arrangement comprises eight wheels, with a first set of four wheels allowing lateral movement of the integrated vehicle in a first direction and a second set of the remaining four wheels allowing lateral movement in a second direction perpendicular to the first direction. One or both sets of wheels in the wheel arrangement may be connected to a wheel lifting mechanism and may be raised and lowered such that the first set of wheels and / or the second set of wheels may be engaged with a respective set of transport rails of the transport rail grid at any one time.

[0085] In an embodiment, the integrated vehicle comprises at least one actuator connected to the openable section of the peripheral sidewall, the actuator being arranged to move the openable section between an open position and a closed position.

[0086] In an embodiment of the integrated vehicle, the openable section comprises at least one pivotable surface connected to the actuator, the pivotable surface may be hinged or pivotally connected at an upper section of the item carrier.

[0087] In one embodiment of the integrated vehicle, the peripheral sidewall comprises four sidewall sections, a bottom section and an open top, one of the sidewall sections being openable so that items may be transferred from the item carrier in a lateral direction.

[0088] In one embodiment, the integrated vehicle is provided with a laterally movable surface arranged to move items contained within the item carrier in a lateral direction towards the openable section of the peripheral side wall and / or a tiltable surface arranged such that items may slide out of the item carrier when the surface is tilted. The laterally movable surface may be a vertical surface arranged to push items out of the container carrier or a horizontal surface of an endless belt onto which items may be placed. The tiltable surface may be a surface of the bottom section that may be tilted by tilting the item carrier by use of an actuator or by tilting the surface independently from the rest of the item carrier.

[0089] In one embodiment of the integrated vehicle, the laterally movable surface is a conveyor belt disposed on a bottom section of the item carrier. The conveyor belt may be disposed to move items contained within the item carrier in a lateral direction out of the item carrier, i.e., such that the items are transferred out of the item carrier in a lateral direction. The conveyor belt may be part of the bottom section.

[0090] The first aspect of the invention may comprise any of the features of the embodiments of the second aspect.

[0091] In a third aspect, the present invention provides a method of consolidating a plurality of items in a storage system, the storage system comprising a storage grid structure in which storage containers are stored, and a plurality of container handling vehicles, the storage grid structure comprising vertical column profiles interconnected at their upper ends by a top rail forming a horizontal top rail grid along which the container handling vehicles can move in two orthogonal directions, the container handling vehicles being capable of retrieving storage containers from the storage grid structure, storing the storage containers therein, and transporting the storage containers on the top rail grid;

[0092] the storage system comprising at least one integrated vehicle, a transport rail grid, an item picking area, and an item delivery station, the integrated vehicle comprising a wheel arrangement for moving the integrated vehicle in two orthogonal directions on the transport rail grid;

[0093] the transfer rail grid comprises transfer rails along which the integrated vehicles may move in two orthogonal horizontal directions;

[0094] the item picking area comprising a first section of a transport rail grid at which an integrated vehicle may be positioned to receive a plurality of items loaded from at least one storage container, and an item picker positioned to load the items from the storage container and transfer them to the integrated vehicle;

[0095] the item delivery station comprises a second section of the transport rail grid at which the integrated vehicle can be positioned to deliver the items received from the storage container to the packaging / processing assembly;

[0096] The integrated vehicle includes an item carrier having an open top and including an openable section arranged such that items may be removed from the item carrier when the integrated vehicle is positioned at the item delivery station, and the method includes:

[0097] - positioning the integrated vehicle on a first section of a transport rail grid;

[0098] - transferring a first item from a first storage container to an item carrier of the integrated vehicle by using a picking device;

[0099] - transferring a second item from the first storage container or from the second storage container to an item carrier of the integrated vehicle by using a picking device;

[0100] - moving the integrated vehicle to a second section of the transfer rail grid;

[0101] - opening the releasable section so that the first and second items are transferred from the item carrier in a lateral or downward direction. Includes.

[0102] In one embodiment of a method for consolidating a plurality of items in a storage system, the first and second items are transferred from an item carrier in a lateral or downward direction onto a transport arrangement.

[0103] In one embodiment of a method for consolidating a plurality of items in a storage system, the first and second items are transferred from the item carrier in a downward direction through an opening disposed below a grid cell of the transport grid.

[0104] In one embodiment of a method for consolidating a plurality of items in a storage system, the first and second items are transferred from an item carrier in a lateral direction onto a conveyor belt.

[0105] In one embodiment, a method of consolidating a plurality of items in a storage system includes transporting first and second items from an item delivery station to a packaging / processing assembly.

[0106] In one embodiment of a method for consolidating a plurality of items in a storage system, a first storage container is disposed on a first container transfer vehicle movable on a transfer rail grid. The first container transfer vehicle carrying the first storage container may be disposed adjacent to the consolidation vehicle in a step preceding the step of transferring the first item from the first storage container to an item carrier of the consolidation vehicle by use of a picking device.

[0107] In an embodiment of a method for consolidating a plurality of items in a storage system, the second storage container is disposed on a second container transfer vehicle movable on a transfer rail grid. The second container transfer vehicle may be disposed adjacent to the consolidation vehicle in a step preceding the step of transferring the second item from the second storage container to an item carrier of the consolidation vehicle by use of a picking device.

[0108] In one embodiment of the method for consolidating a plurality of items in a storage system, the consolidation vehicle and the container transfer vehicle have a horizontal perimeter that fits within a horizontal area defined by grid cells of the transfer rail grid, i.e., a maximum horizontal perimeter.

[0109] In one embodiment of a method for consolidating multiple items in a storage system, a vertical column configuration defines a plurality of storage columns, the storage containers are stored one above the other in a vertical stack, and a container handling vehicle is capable of retrieving the storage containers from the storage columns and storing the storage containers therein.

[0110] In one embodiment of the method for consolidating multiple items in a storage system, the vertical column configuration defines at least one transfer column along which a container handling vehicle may transfer storage containers between the upper rail grid and a lower level of the storage grid structure.

[0111] In one embodiment of a method for consolidating multiple items in a storage system, a first storage container is placed on a first container transfer vehicle by positioning the first container transfer vehicle on a section of a transfer rail grid below at least one transfer column, and the first storage container is transferred from the upper rail grid to a container carrier of the first container transfer vehicle by a container handling vehicle.

[0112] In one embodiment of a method for consolidating multiple items in a storage system, a second storage container is placed on a second container transfer vehicle by positioning the second container transfer vehicle on a section of the transfer rail grid below at least one transfer column, and the second storage container is transferred from the upper rail grid to a container carrier of the second container transfer vehicle by a container handling vehicle.

[0113] The third aspect of the invention may comprise any of the features of the embodiments of the first and second aspects.

[0114] In a fourth aspect, the present invention provides a method of consolidating a plurality of items in a storage system, the storage system comprising a storage grid structure in which storage containers are stored, and a plurality of container handling vehicles, the storage grid structure comprising vertical column profiles interconnected at their upper ends by a top rail forming a horizontal top rail grid along which the container handling vehicles can move in two orthogonal directions, the container handling vehicles being capable of retrieving storage containers from the storage grid structure, storing the storage containers therein, and transporting the storage containers on the top rail grid;

[0115] the storage system includes a first integrated vehicle, a second integrated vehicle, a transfer rail grid, a first item picking area, a second item picking area, and an item delivery station, the transfer rail grid including a transfer rail along which the integrated vehicles may move in two orthogonal horizontal directions;

[0116] each item picking area comprising a section of a transport rail grid upon which an integrated vehicle may be positioned to receive at least one item loaded from at least one storage container, and an item picker arranged to load an item from the storage container and transfer it to either of the first and second integrated vehicles;

[0117] the item delivery station comprises a section of a transport rail grid at which the integrated vehicle can be positioned to deliver at least one item received in the first or second item picking area to the packaging / processing assembly;

[0118] Each integrated vehicle comprises an item carrier having an open top and including an openable section arranged such that items may be transferred from the item carrier when the integrated vehicle is positioned at the item delivery station, and the method comprises:

[0119] - positioning a first integrated vehicle in a first item picking area;

[0120] - transferring a first item from a storage container to an item carrier of a first integrated vehicle by use of a picking device;

[0121] - positioning a second integrated vehicle in a second item picking area;

[0122] - transferring a second item from the storage container to an item carrier of a second integrated vehicle by use of a picking device;

[0123] - moving the first and second integrated vehicles to an item delivery station;

[0124] - opening openable sections of the first and second integration vehicles such that the first and second items are transferred from the respective item carriers in a sideways or downward direction and integrated in a packaging / processing assembly; Includes.

[0125] In one embodiment of the fourth aspect, the steps of moving the first and second integrated vehicles to the item delivery station and opening the openable section are successive steps;

[0126] - moving a first integrated vehicle to an item delivery station;

[0127] - opening an openable section of the first integrated vehicle such that the first item is transferred from the item carrier in a lateral or downward direction;

[0128] - moving the second integrated vehicle to an item delivery station;

[0129] - opening an openable section of the second integration vehicle so that the second item may be transferred from the item carrier in a sideways or downward direction and integrated with the first item in the packaging / processing assembly; Includes.

[0130] In certain embodiments of the fourth aspect, the first and second items are transferred from their respective item carriers in a sideways or downward direction onto the transport arrangement.

[0131] In certain embodiments of the fourth aspect, the first and second items are transferred from their respective item carriers in a downward direction through openings disposed below grid cells of the transport grid.

[0132] In certain embodiments of the fourth aspect, the first and second items are transferred from the item carrier in a lateral direction onto the conveyor belt.

[0133] In an embodiment, the fourth aspect includes conveying the first and second items from the item delivery station to a packaging / processing assembly.

[0134] In an embodiment of the fourth aspect, the first item is transferred at a first item picking station from a first storage container disposed on a first container transfer vehicle movable on a transfer rail grid. The first container transfer vehicle carrying the first storage container may be disposed adjacent to the first integrated vehicle in a step preceding the step of transferring the first item from the first storage container to an item carrier of the first integrated vehicle by use of a picking device.

[0135] In an embodiment of the fourth aspect, the second item is transferred at a second item picking station from a second storage container disposed on a second container transfer vehicle movable on a transfer rail grid. The second container transfer vehicle may be disposed adjacent to the second integrated vehicle in a step preceding the step of transferring the second item from the second storage container to an item carrier of the second integrated vehicle by use of a picking device.

[0136] In certain embodiments of the fourth aspect, the integrated vehicle and the container transfer vehicle have a horizontal perimeter that falls within a horizontal area defined by grid cells of the transfer rail grid, i.e., a maximum horizontal perimeter.

[0137] In one embodiment of the fourth aspect, the vertical column configuration defines a plurality of storage columns, the storage containers are stored one on top of the other in a vertical stack, and a container handling vehicle is capable of retrieving the storage containers from the storage columns and storing the storage containers therein.

[0138] In certain embodiments of the fourth aspect, the vertical column configuration defines at least one transfer column along which a container handling vehicle may transfer storage containers between the upper rail grid and a lower level of the storage grid structure.

[0139] In one embodiment of the fourth aspect, the first storage container is placed on the first container transfer vehicle by positioning the first container transfer vehicle on a section of the transfer rail grid below at least one transfer column, and the first storage container is transferred from the upper rail grid to a container carrier of the first container transfer vehicle by a container handling vehicle.

[0140] In one embodiment of the fourth aspect, the second storage container is placed on the second container transfer vehicle by positioning the second container transfer vehicle on a section of the transfer rail grid below the at least one transfer column, and the second storage container is transferred from the upper rail grid to a container carrier of the second container transfer vehicle by a container handling vehicle.

[0141] In an embodiment of the fourth aspect, a storage system includes a first storage grid structure and a second storage grid structure, and a first item is transferred from a storage container of the first storage grid structure and a second item is transferred from a storage container of the second storage grid structure.

[0142] In a fifth aspect, the present invention provides a method of consolidating a plurality of items in a storage system, the storage system comprising a storage grid structure in which storage containers are stored, and a plurality of container handling vehicles, the storage grid structure comprising vertical column profiles interconnected at their upper ends by a top rail forming a horizontal top rail grid along which the container handling vehicles can move in two orthogonal directions, the container handling vehicles being capable of retrieving storage containers from the storage grid structure, storing the storage containers therein, and transporting the storage containers on the top rail grid;

[0143] The storage system includes at least one integrated vehicle, a transport rail grid, an item picking area, and an item delivery station, the transport rail grid including a transport rail along which the integrated vehicle may move in two orthogonal horizontal directions;

[0144] the item picking area comprising a first section of a transport rail grid at which an integrated vehicle may be positioned to receive a plurality of items loaded from at least one storage container, and an item picker positioned to load the items from the storage container and transfer them to the integrated vehicle;

[0145] the item delivery station comprises a second section of the transport rail grid at which the integrated vehicle can be positioned to deliver the items received from the storage container to the packaging / processing assembly;

[0146] The integrated vehicle includes an item carrier characterized by a conveyor on which open-top packaging boxes may be positioned such that the boxes (and items) may be transferred from the item carrier when the integrated vehicle is positioned at an item delivery station, and the method includes:

[0147] - positioning the integrated vehicle on a first section of a transport rail grid;

[0148] - transferring a first item from a first storage container to a packaging box disposed on an item carrier of the integrated vehicle by using a picking device;

[0149] - transferring a second item from the first storage container or from the second storage container to a packaging box on the integrated vehicle by using a picking device;

[0150] - moving the integrated vehicle to a second section of the transfer rail grid;

[0151] - actuating a conveyor of the integrated vehicle such that the packaging box (and the first and second items) are transferred (or transported) from the item carrier in a lateral direction; Includes.

[0152] In certain embodiments of the fifth aspect, the packaging box (and the first and second items) are transferred (or transported) from the item carrier in a lateral direction onto the transport arrangement.

[0153] The term "removed from" may alternatively be replaced by the term "transferred from," as the terms are considered to be synonymous. The present specification also provides, for example, the following: (Item 1) A storage system (1), comprising: a storage grid structure (104) in which storage containers (106) are stored; Multiple container handling vehicles (200, 300) Equipped with the storage grid structure comprises vertical column profiles (102) interconnected at their upper ends by top rails (110, 111) forming a horizontal top rail grid (108), on which the container handling vehicles (200, 300) are movable in two orthogonal directions; the container handling vehicle is capable of retrieving storage containers (106) from the storage grid structure (104), storing storage containers in the storage grid structure (104), and transporting the storage containers on the upper rail grid; The storage system (1) is characterized in that it comprises at least one integrated vehicle (6), a transport rail grid (5), an item picking area (7) and an item delivery station (8), - said integrated vehicle comprises a wheel arrangement (32a, 32b) for moving said integrated vehicle (6) in two orthogonal directions on said transfer rail grid (5); - said transfer rail grid (5) comprises transfer rails (110', 111') along which said integrated vehicles (6) are movable in two orthogonal horizontal directions, - said item picking area comprises a first section (9) of said transport rail grid in which said integrated vehicle (6) can be positioned to receive a plurality of items (21) loaded from at least one storage container (106), and an item picker (11) arranged to load said items from said storage container (106) and transfer them to said integrated vehicle (6), - said item delivery station comprises a second section (10) of said transport rail grid (5), on which said integrated vehicle can be positioned to deliver items received from said storage containers to a packaging / processing assembly (12), - a storage system, wherein the integrated vehicle (6) is provided with an item carrier (13), the item carrier (13) being arranged such that items can be transferred from the item carrier (13) when the integrated vehicle is positioned at the item delivery station. (Item 2) 2. The storage system of claim 1, wherein the upper rail grid (108) is separate from the transfer rail grid (5). (Item 3) 3. The storage system according to item 2, wherein the transfer rail grid (5) is arranged at a level lower than the level of the upper rail grid (108). (Item 4) 4. A storage system according to any of items 1-3, wherein when the integrated vehicle is positioned at the item delivery station, items can be transferred from the item carrier (13) in a lateral or downward direction. (Item 5) The storage system of any of items 1-4, wherein the item picker is equipped with a robotic picking arm (11). (Item 6) The storage system of any of items 1-5, wherein the item delivery station (8) is provided with an opening (19) or conveyor (20) positioned to guide items transferred from the integrated vehicle to the packaging / processing assembly. (Item 7) 7. The storage system according to any of items 1-6, wherein the transfer rails (110', 111') are dual track rails such that two integrated vehicles (6) can pass each other on adjacent grid cells (122') of the transfer rail grid. (Item 8) 8. The storage system of any of items 1-7, wherein the integrated vehicle (6) has a horizontal perimeter that fits within a horizontal area defined by grid cells (122') of the transport rail grid (5). (Item 9) A storage system as described in any of items 1-8, wherein the item carrier (13) has an open top (17) and the item carrier (13) is provided with openable sections (15, 16) arranged such that items can be removed from the item carrier (13) when the openable sections are open. (Item 10) 10. The storage system of claim 9, wherein the item carrier (13) comprises a peripheral side wall (14, 15) and a bottom section (16, 22), and the openable section comprises a section of the peripheral side wall (15) or the bottom section (16). (Item 11) 11. The storage system of claim 10, wherein the integrated vehicle comprises an actuator (18) connected to the openable section of the peripheral side wall (15) or the bottom section (16), the actuator being arranged to move the section of the side wall (15) or the section of the bottom section (16) between an open position and a closed position. (Item 12) 12. The storage system according to item 10 or 11, wherein the openable section of the peripheral side wall or the bottom section is provided with a hinged surface (15, 16). (Item 13) 13. A storage system according to any of claims 1-12, comprising at least one container transfer vehicle (23) having a storage container carrier (38) and a wheel arrangement (32a, 32b) arranged to move the container transfer vehicle (23) in two orthogonal directions on the transfer rail grid (5), the transfer rail grid comprising a third section (24) arranged below a transfer column (119, 120) of the storage grid so that a container handling vehicle (200, 300) can raise or lower a storage container (106) between the storage container carrier (38) and the upper rail grid (108). (Item 14) The integrated vehicle (6) comprises a wheel arrangement (32a, 32b) and an item carrier (13), - said wheel arrangement is for moving said integrated vehicle (6) in two orthogonal directions on a transfer rail grid (5); - said item carrier (13) comprises peripheral side walls (14, 15), a bottom section (22) and an open top (17), a section of said peripheral side wall (15) being openable such that items can be transferred from said item carrier (13) in a lateral direction through said openable section; An integrated vehicle (6) for a storage system according to any of items 1-13, characterized in that: (Item 15) Item 15. An integrated vehicle as described in item 14, comprising an actuator (18) connected to the openable section (15) of the peripheral side walls (14, 15), the actuator being arranged to move the openable section between an open position and a closed position when the openable section is in an open position so that items can be transferred from the item carrier (13). (Item 16) 16. An integrated vehicle as described in item 14 or 15, comprising a laterally movable surface (22) arranged to move items contained in the item carrier (13) in a lateral direction towards the openable section (15) of the peripheral side walls (14, 15) and / or a tiltable surface in the bottom section, the tiltable surface arranged such that items can slide out of the item carrier when the surface is tilted. (Item 17) Item 17. The integrated vehicle of item 16, wherein the laterally movable surface is a conveyor belt (22) disposed on a bottom section of the item carrier. (Item 18) 1. A method of consolidating a plurality of items in a storage system, comprising: The storage system includes: a storage grid structure (104) in which storage containers (106) are stored; Multiple container handling vehicles (200, 300) Equipped with the storage grid structure comprises vertical column profiles (102) interconnected at their upper ends by top rails (110, 111) forming a horizontal top rail grid (108), on which the container handling vehicles (200, 300) are movable in two orthogonal directions; the container handling vehicle is capable of retrieving storage containers (106) from the storage grid structure (104), storing storage containers in the storage grid structure (104), and transporting the storage containers on the upper rail grid; The storage system comprises at least one integrated vehicle (6), a transport rail grid (5), an item picking area (7), and an item delivery station (8); the integrated vehicle comprises a wheel arrangement (32a, 32b) for moving the integrated vehicle (6) in two orthogonal directions on the transfer rail grid (5); the transfer rail grid (5) comprises transfer rails (110', 111') along which the integrated vehicles (6) can move in two orthogonal horizontal directions; the item picking area comprises a first section (9) of the transport rail grid in which the integrated vehicle (6) can be positioned to receive a plurality of items (21) loaded from at least one storage container (106), and an item picker (11) arranged to load the items from the storage container (106) and transfer them to the integrated vehicle (6); the item delivery station comprises a second section (10) of the transport rail grid (5), on which the integrated vehicle can be positioned to deliver items received from the storage containers to a packaging / processing assembly (12); the integrated vehicle (6) comprises an item carrier (13), the item carrier (13) having an open top (17), the item carrier (13) comprising openable sections (15, 16) arranged such that items can be removed from the item carrier (13) when the integrated vehicle is positioned at the item delivery station; The method comprises: - positioning an integrated vehicle on a first section of the transfer rail grid; - transferring a first item from a first storage container to the item carrier of the integrated vehicle by using the picking device; - transferring a second item from the first storage container or from a second storage container to the item carrier of the integrated vehicle by using the picking device; - moving the integrated vehicle to the second section of the transfer rail grid; - opening the openable section so that the first and second items are transferred from the item carrier in a lateral or downward direction. A method comprising: [Brief description of the drawings]

[0154] The invention is described in detail below, by way of example only, with reference to the following drawings, in which: [Figure 1] Figures 1 and 2 are perspective views of a prior art automated storage and retrieval system, with Figures 1A and 2A showing the complete system and Figures 1B and 2B showing an example of a prior art container handling vehicle suitable for use in the system. [Diagram 2] Figures 1 and 2 are perspective views of a prior art automated storage and retrieval system, with Figures 1A and 2A showing the complete system and Figures 1B and 2B showing an example of a prior art container handling vehicle suitable for use in the system.

[0155] [Diagram 3] FIG. 3 is a schematic top view of a grid cell defined by dual track rails.

[0156] [Figure 4] FIG. 4 is a perspective view of a first exemplary storage system according to the present invention.

[0157] [Diagram 5] FIG. 5 is a perspective view of a picking station of the storage system of FIG.

[0158] [Figure 6] 6 is a perspective view of an item delivery station of the storage system of FIG. 3. FIG.

[0159] [Figure 7] FIG. 7 is a detailed view of the item delivery station of FIG.

[0160] [Figure 8] FIG. 8 is a perspective view of an integrated vehicle used in the storage system of FIG.

[0161] [Figure 9] FIG. 9 is a top side perspective view of an exemplary integrated vehicle positioned at an item delivery station.

[0162] [Figure 10] 10 is a top side perspective view of the integrated vehicle of FIG. 8 during emptying of items at an item delivery station.

[0163] [Figure 11] FIG. 11 is a perspective cross-sectional view of the integrated vehicle of FIGS.

[0164] [Figure 12] FIG. 12 is a perspective view of a storage grid featuring a container transfer vehicle positioned on the transfer grid to receive storage containers from a container handling vehicle.

[0165] [Figure 13] FIG. 13 is a perspective view of a second exemplary storage system in accordance with the present invention.

[0166] [Figure 14] FIG. 14 is a perspective view of a picking station of the storage system of FIG.

[0167] [Figure 15] FIG. 15 is a perspective view of an exemplary integrated vehicle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0168] In the following, embodiments of the present invention will be discussed in more detail with reference to the attached drawings. It should be understood, however, that the drawings are not intended to limit the present invention to the subject matter depicted in the drawings. Moreover, even if some of the features are described only in relation to the system, it is clear that they are equally valid for the related method and vice versa.

[0169] The present invention aims to provide a storage system with improved and efficient consolidation of stowed items.

[0170] A first exemplary embodiment of a storage system according to the present invention is shown in Figures 4-7. The storage system features a storage grid structure 104 on which a plurality of container handling vehicles 300 are disposed.

[0171] The storage grid structure includes a vertical column exterior 102 defining a number of storage columns 105 in which storage containers 106 are stored one above the other in a vertical stack 107. The storage grid will feature at least one transfer column (see FIG. 12 for an exemplary transfer column) arranged to allow transport of storage containers into and out of the storage grid.

[0172] The column profiles 102 are interconnected at their upper ends by upper rails 110, 111 which form a horizontal upper rail grid 108 along which a container handling vehicle 300 can move in two orthogonal directions to retrieve storage containers 106 from the storage columns 105, store the storage containers therein, and transport the storage containers on the storage grid structure 104.

[0173] To obtain efficient consolidation of items loaded from the storage containers, the storage system features a number of consolidation vehicles 6, a transport rail grid 5, an item picking area 7, and an item delivery station 8.

[0174] The transfer rail grid 5 consists of transfer rails 110', 111' along which the integrated vehicles 6 can move in two orthogonal horizontal directions.

[0175] The item picking area 7 comprises a first section 9 of a transfer rail grid on which the integrated vehicles 6 are positioned to receive items 21 loaded from any of the storage containers 106 located within reach of the robotic picking arms 11 (i.e., item pickers). Each of the robotic picking arms is positioned to load items from a storage container 106 located beneath the robotic picker arm and transfer them to the integrated vehicle 6. When fulfilling an order comprising multiple items, the multiple items are transferred to the same integrated vehicle 6.

[0176] Once all items in an order have been transferred to the integrated vehicle, the integrated vehicle is moved on the transport rail grid to an item delivery station for further processing of the order. The item delivery station features a second section 10 of the transport rail grid 5, where the integrated vehicle 6 can be positioned to deliver the items of the order received from the storage container to a packaging / processing assembly 12. The combination of the integrated vehicle 6 and the transport rail grid 5 thus provides for very flexible positioning of the item delivery station 8 and the packaging / processing assembly 12.

[0177] In the example storage system shown in Figures 4-7, items 21 may be delivered to the packaging / processing assembly 12 via a belt conveyor 20 or an opening 19. The preferred manner in which items are delivered to the packaging / processing assembly 12 may depend on the layout of the storage system and the available space in the building that houses the storage system.

[0178] A detailed view of an exemplary integrated vehicle 6 used in the storage system of Figures 4-7 is shown in Figure 8. The integrated vehicle 6 comprises an item carrier 13 having an open top 17, four side walls 14, 15 (i.e., peripheral side walls), and a conveyor belt 22 (i.e., a laterally movable surface and / or item transfer assembly) disposed at a bottom section of the item carrier. One of the side walls 15 is hinged at an upper section of the item carrier 13 and connected to an actuator 18 such that the side wall can be moved between an open position and a closed position. As illustrated in Figures 6 and 7, items 21 disposed within the item carrier 13 can be transferred out when the conveyor belt 22 is activated and the openable side wall 15 is in the open position.

[0179] The integrated vehicle 6 features a motorized wheel arrangement 32a, 32b that allows the vehicle to move in two orthogonal directions on the transfer grid 5. The wheel arrangement is similar to the wheel arrangements of prior art container handling vehicles 200, 300, for example as disclosed in NO 317366 B1 and WO2015 / 193278A1, and can optionally be motorized by use of hub motors as disclosed in WO2016 / 120075A1.

[0180] The transfer rail grid is composed of dual track rails 110', 111' and the integrated vehicles 6 have a horizontal perimeter that fits within the horizontal area defined by grid cells 122' of the transfer rail grid 5. This solution is very efficient since two integrated vehicles 6 can pass each other on any adjacent grid cells 122' of the transfer rail grid 5, i.e., it does not require much from the shortest path between two positions on the transfer grid. Furthermore, multiple integrated vehicles 6 can be placed on adjacent grid cells in the item picking area, whereby the robotic picker arm can reach multiple integrated vehicles by traveling the shortest possible distance between the integrated vehicles and the storage containers. The latter provides a very time-efficient picking process.

[0181] Depending on the type of container handling vehicles 200, 300 being used on the storage grid structure, the upper rail grid 108 may be the same as or different from the transfer rail grid 5. The upper rail grid may differ from the transfer rail grid by, for example, being characterized in that a first set of rails are single track rails and a second set of rails are dual track rails, as explained in the Background section. However, independent of whether the upper rail grid is the same as the transfer rail grid, the rail grids are arranged separately from each other such that container handling vehicles 300 are prevented from entering the transfer rail grid 5 and integrated vehicles 6 are prevented from entering the upper rail grid 108. In the exemplary storage system of Figures 4-7, the transfer rail grid 5 is separate from the upper rail grid 108 by being arranged at different levels. Having the rail grids separated is highly advantageous for several reasons. A first advantage of separating the rail grids 5, 108 is that the consolidation operations performed on the transfer rail grid can be stopped without affecting the operations performed on the storage grid 104 that are not related to the consolidation operations, such as retrieving storage containers and transporting them to a manually operated picking / feed station (not shown). This ensures that the storage system has a minimum downtime. It should be noted that if the container handling vehicles 200, 300 had access to the transfer rail grid, the entire storage system would need to be shut down, for example to perform an inspection of the equipment located on the transfer rail grid. A second advantage is that the control system can be simplified, since the consolidation vehicles can be controlled and moved without having to consider the movement of the container handling vehicles.

[0182] In other embodiments of the storage system, the transport rail grid and the upper rail grid may be at the same level but separate by having a blocking element, e.g. a fence, located between the two grids or by being located at a distance from each other.

[0183] A second exemplary embodiment of an integrated vehicle 6' is shown in Figures 9-11. The integrated vehicle 6' comprises an item carrier 13, characterized by a wheel arrangement 32a, 32b that allows the vehicle to move in two orthogonal directions on the transport grid 5, and has an open top 17, four side walls 14, 15 (i.e. peripheral side walls) and an openable bottom section 16 (i.e. item transfer assembly). The bottom section 16 is connected to an actuator 18 arranged to move the bottom section between a closed position (see Figure 9) and an open position (see Figures 10 and 11). To allow space for the openable bottom section, the wheel arrangement is motorized by hub motors at each wheel.

[0184] In use, the consolidation vehicle 6' may first be positioned at an item picking area to receive items to be consolidated and then moved to an item delivery station in a position above the opening 19 for delivery of the items to the packaging / processing assembly 12 by opening the bottom section 16. Although not shown, the opening 19 may in some cases be positioned above a conveyor for further transport of items 21 to the packaging / processing assembly 12.

[0185] A third exemplary embodiment of the integrated vehicle 6'' is shown in FIG. 15. The integrated vehicle 6'' is equipped with an item carrier 13, characterized by a wheel arrangement 32a, 32b that allows the vehicle to move in two orthogonal directions on the transport grid 5, and equipped with a roller conveyor 25 (i.e., item transport assembly) arranged in the bottom section of the vehicle. The integrated vehicle 6'' is particularly suitable for direct integration of items, for example in open-top packaging boxes 26 (schematically depicted in dashed lines) arranged on the item carrier 13, but is also suitable for the transport of larger items to be integrated in the packaging / processing assembly 12. In use, packaging boxes or large items can be transferred from the integrated vehicle to the conveyor 20 at the item delivery station 8 by activating the roller conveyor 25.

[0186] The consolidation operations performed by the exemplary storage system of Figures 4-7 include the steps of positioning the integrated vehicle 6, 6' in a first section 9 of the transport rail grid 5, transferring a first item 21 from a first storage container 106 to an item carrier 13 of the integrated vehicle 6, 6' by using a robotic picking arm, transferring a second item 21 from the first storage container 106 or from the second storage container 106 to the item carrier 13 of the integrated vehicle 6, 6' by using the robotic picking arm, and moving the integrated vehicle 6, 6' to a second section 10 of the transport rail grid 5.

[0187] and opening the openable sidewall 15 or bottom section 16 (i.e. opening an openable section of the item carrier) so that the first and second items 21 may be removed from the item carrier 13 in a lateral or downward direction. Once removed from the item carrier, the items may be transferred to a conveying arrangement, such as a conveyor belt or rollers.

[0188] In an alternative consolidation operation, consolidation of items may also be performed at the packaging / processing assembly 12. For example, by transferring a first item to a first consolidation vehicle 6, 6' and a second item to a second consolidation vehicle 6, 6'. The first and second consolidation vehicles may then be moved to transfer the first and second items, respectively, at the same item delivery station 8 such that the items are consolidated at the item delivery station 8 or the packaging / processing assembly 12. An alternative consolidation process may involve multiple consolidation vehicles, each used to transport at least one item.

[0189] A second exemplary embodiment of the storage system is shown in Figures 12-14. In the second exemplary embodiment, a storage container 106 containing an item 21 to be loaded is first transferred from a storage grid 104 to a container transfer vehicle 23 located on a third section 24 of a transfer rail grid 5 by use of a container handling vehicle 300. The third section 24 of the transfer rail grid 5 extends below the transfer column of the storage grid 104 and is connected to a first section 9 of the transfer rail grid, whereby the container transfer vehicle can move the storage container to the item picking area. The second exemplary embodiment of the storage system includes an item delivery station 8 (not shown) as described with respect to the storage system of Figures 4-7 having a second section 10 of the transfer rail grid 5 connected to the first section 9 of the transfer rail grid 5 to enable movement of the integrated vehicle from the item picking area 7 to the item delivery station 8.

[0190] The integrated vehicle features a wheel arrangement 32a, 32b that allows the vehicle to move in two orthogonal directions on the transfer rail grid 5, and is equipped with a storage container carrier 38 for receiving storage containers lowered through the transfer column by the container handling vehicle 300. In the exemplary container transfer vehicle 23, the container carrier 38 features an open top 17 and four side walls 14. However, alternative container carriers are also envisaged. The requirements for the container carrier are that it can keep the storage container in a stable position on the container transfer vehicle during movement on the grid, and that the container carrier can receive the storage container from above and provide topside access to the items in the storage container. Like the integrated vehicle 6, the container transfer vehicle 23 has a maximum horizontal perimeter that fits within the horizontal area defined by the grid cells 122′ of the transfer rail grid 5. This allows for a compact arrangement of multiple adjacent container transfer vehicles 23 and the integrated vehicle 6 in the item picking area 7. The compact arrangement ensures that the distance that the robotic picking arm 11 has to travel to load items from storage containers located on the container transfer vehicle 23 and transfer them to the consolidation vehicle 6 is as short as possible. By moving the storage containers to the item picking area by use of the container transfer vehicle, a more flexible positioning of the item picking area is obtained compared to the storage system of Figures 4-7.

[0191] The integrated operations performed by the exemplary storage system of Figures 12-14 include the steps described above with respect to the exemplary storage system of Figures 4-7, preceded by the steps of retrieving a first storage container 106 having a first item 21 from the storage grid 104, accommodating the first storage container onto a first container transfer vehicle 23, and positioning the first container transfer vehicle 23 in a first section 9 of the transfer rail grid 5, and optionally the steps of retrieving a second storage container 106 having a second item 21 from the storage grid 104, accommodating the second storage container onto the second container transfer vehicle 23, and positioning the second container transfer vehicle 23 in the first section 9 of the transfer rail grid 5.

[0192] In addition to the item picking area 7 where items may be loaded by the automatic robotic picking arm 11, the example storage system of FIGS. 12-14 also features a manual picking / stocking station for unsuitable items for picking by the robotic picking arm 11. If an order to be consolidated comprises such an unsuitable item, the consolidation vehicle 6, 6', 6'' may be positioned at the manual picking / stocking station to receive the item from an operator before moving, for example, to the delivery station 8 or to the item picking area 7 to receive further items to be consolidated.

[0193] The exemplary storage system features a single storage grid structure 104. However, the present invention is also highly advantageous in similar storage systems that feature at least two separate storage grid structures. In such storage systems, items stored in different storage grid structures may be easily consolidated. For example, with reference to the consolidation operation described above, a first storage container may be retrieved from the first storage grid structure, while a second storage container is retrieved from the second storage grid structure.

[0194] In a further embodiment of the inventive storage system, the transport rail grid is arranged so that packages / items from at least one prior art or third party storage system can be transported onto the integrated vehicle for consolidation and / or packaging / processing in the packaging / processing assembly 12. (Reference Number) [Table 1-1] [Table 1-2]

Claims

1. A storage system (1), comprising: a storage grid structure (104) in which storage containers (106) are stored; A plurality of container handling vehicles (200, 300) Equipped with said storage grid structure comprises vertical column profiles (102) interconnected at their upper ends by top rails (110, 111) forming a horizontal top rail grid (108), on which said container handling vehicles (200, 300) are movable in two orthogonal directions; the container handling vehicle is capable of retrieving storage containers (106) from the storage grid structure (104), storing storage containers in the storage grid structure (104), and transporting the storage containers on the upper rail grid; The storage system (1) is characterized in that it comprises at least one integrated vehicle (6), a transport rail grid (5), an item picking area (7) and an item delivery station (8), - said integrated vehicle comprises a wheel arrangement (32a, 32b) for moving said integrated vehicle (6) in two orthogonal directions on said transfer rail grid (5); - said transfer rail grid (5) comprises transfer rails (110', 111') along which said integrated vehicles (6) are movable in two orthogonal horizontal directions; - said item picking area comprises a first section (9) of said transport rail grid in which said integrated vehicle (6) can be positioned to receive a plurality of items (21) loaded from at least one storage container (106), and an item picker (11) arranged to load said items from said storage container (106) and transfer them to said integrated vehicle (6), - said item delivery station comprises a second section (10) of said transport rail grid (5), on which said integrated vehicle can be positioned to deliver items received from said storage containers to a packaging / processing assembly (12); - a storage system, wherein the integrated vehicle (6) is provided with an item carrier (13), the item carrier (13) being arranged such that items can be transferred from the item carrier (13) when the integrated vehicle is positioned at the item delivery station.

2. 2. The storage system of claim 1, wherein the upper rail grid (108) is separate from the transport rail grid (5).

3. 3. The storage system according to claim 2, wherein the transport rail grid (5) is arranged at a level lower than the level of the upper rail grid (108).

4. A storage system according to any of claims 1 to 3, wherein when the integrated vehicle is positioned at the item delivery station, items can be transferred from the item carrier (13) in a lateral or downward direction.

5. A storage system according to any preceding claim, wherein the item picker comprises a robotic picking arm (11).

6. A storage system as described in any one of claims 1 to 5, wherein the item delivery station (8) is provided with an opening (19) or conveyor (20) positioned to guide items transferred from the integrated vehicle to the packaging / processing assembly.

7. The storage system according to any one of claims 1 to 6, wherein the transfer rails (110', 111') are dual track rails such that two integrated vehicles (6) can pass each other on adjacent grid cells (122') of the transfer rail grid.

8. A storage system according to any one of claims 1 to 7, wherein the integrated vehicles (6) have a horizontal perimeter that fits within a horizontal area defined by grid cells (122') of the transport rail grid (5).

9. A storage system as claimed in any one of claims 1 to 8, wherein the item carrier (13) has an open top (17), and the item carrier (13) is provided with openable sections (15, 16) arranged such that when the openable sections are opened, items can be removed from the item carrier (13).

10. 10. The storage system of claim 9, wherein the item carrier (13) comprises a peripheral side wall (14, 15) and a bottom section (16, 22), and the openable section comprises a section of the peripheral side wall (15) or the bottom section (16).

11. 11. The storage system of claim 10, wherein the integrated vehicle comprises an actuator (18) connected to the openable section of the peripheral side wall (15) or the bottom section (16), the actuator being arranged to move the section of the side wall (15) or the section of the bottom section (16) between an open position and a closed position.

12. 12. A storage system according to claim 10 or 11, wherein the openable section of the peripheral side wall or the bottom section is provided with a hinged surface (15, 16).

13. 13. A storage system according to any of claims 1 to 12, comprising at least one container transfer vehicle (23) having a storage container carrier (38) and a wheel arrangement (32a, 32b) arranged to move the container transfer vehicle (23) in two orthogonal directions on the transfer rail grid (5), the transfer rail grid comprising a third section (24) arranged below a transfer column (119, 120) of the storage grid structure (104) so ​​that a container handling vehicle (200, 300) can raise or lower a storage container (106) between the storage container carrier (38) and the upper rail grid (108).

14. The integrated vehicle (6) comprises a wheel arrangement (32a, 32b) and an item carrier (13), - said wheel arrangement is for moving said integrated vehicle (6) in two orthogonal directions on a transfer rail grid (5); - said item carrier (13) comprises peripheral side walls (14, 15), a bottom section (22) and an open top (17), a section of said peripheral side wall (15) being openable such that items can be transferred from said item carrier (13) in a lateral direction through the openable section; An integrated vehicle (6) for a storage system according to any of claims 1 to 13, characterized in that:

15. 15. An integrated vehicle as claimed in claim 14, comprising an actuator (18) connected to the openable section (15) of the peripheral side walls (14, 15), the actuator being arranged to move the openable section between an open position and a closed position when the openable section is in an open position so that items can be removed from the item carrier (13).

16. 16. An integrated vehicle as claimed in claim 14 or 15, comprising a laterally movable surface (22) arranged to move items contained in the item carrier (13) in a lateral direction towards the openable section (15) of the peripheral side walls (14, 15) and / or a tiltable surface in the bottom section, the tiltable surface arranged such that items can slide out of the item carrier when the surface is tilted.

17. 17. The integrated vehicle of claim 16, wherein the laterally movable surface is a conveyor belt (22) disposed on a bottom section of the item carrier.

18. 1. A method of consolidating a plurality of items in a storage system, comprising: The storage system includes: a storage grid structure (104) in which storage containers (106) are stored; A plurality of container handling vehicles (200, 300) Equipped with said storage grid structure comprises vertical column profiles (102) interconnected at their upper ends by top rails (110, 111) forming a horizontal top rail grid (108), on which said container handling vehicles (200, 300) are movable in two orthogonal directions; the container handling vehicle is capable of retrieving storage containers (106) from the storage grid structure (104), storing storage containers in the storage grid structure (104), and transporting the storage containers on the upper rail grid; The storage system comprises at least one integrated vehicle (6), a transport rail grid (5), an item picking area (7), and an item delivery station (8), said integrated vehicle comprising a wheel arrangement (32a, 32b) for moving said integrated vehicle (6) in two orthogonal directions on said transfer rail grid (5); said transfer rail grid (5) comprising transfer rails (110', 111') along which said integrated vehicles (6) can move in two orthogonal horizontal directions; the item picking area comprises a first section (9) of the transport rail grid in which the integrated vehicle (6) can be positioned to receive a plurality of items (21) loaded from at least one storage container (106), and an item picker (11) arranged to load the items from the storage container (106) and transfer them to the integrated vehicle (6); said item delivery station comprises a second section (10) of said transport rail grid (5), on which said integrated vehicle can be positioned to deliver items received from said storage containers to a packaging / processing assembly (12); the integrated vehicle (6) comprises an item carrier (13), the item carrier (13) having an open top (17), the item carrier (13) comprising openable sections (15, 16) arranged such that the items can be transferred from the item carrier (13) when the integrated vehicle is positioned at the item delivery station; The method comprises: - positioning an integrated vehicle on a first section of said transport rail grid; - transferring a first item from a first storage container to the item carrier of the integrated vehicle by using the item picker; - transferring a second item from the first storage container or from a second storage container to the item carrier of the integrated vehicle by using the item picker; - moving said integrated vehicle to said second section of said transfer rail grid; - opening the openable section so that the first and second items are transferred from the item carrier in a lateral or downward direction; A method comprising:

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