STORAGE SYSTEM, METHOD, AND DEVICE

Abstract

The storage system comprises at least one storage floor comprising a track network based on a grid system, the track network (306) comprising a first set (22A) of track members (16) extending in a first (x) direction and a second set (22B) of track members (16) extending in a second (y) direction, the second set (22B) of track members (16) extending transversely to the first set (22A) of track members (16) in a substantially horizontal plane, the track network (306) comprising an access aisle (2) and a storage aisle (2), the storage aisle (2) comprising one or more storage locations (1) for receiving storage containers (200) and at least one load handling device operative on the track network (306) to lift and transport the storage containers (200), the storage locations (1) comprising support means for supporting the storage containers (200).

Description

[Technical field]

[0001] The present invention relates to storage systems, methods and devices. More particularly, the present invention relates to automated article storage and retrieval systems, methods and associated devices. [Background technology]

[0002] Methods of handling containers stacked in rows have been known for decades. Some such systems, as described, for example, in US 2,701,065 to Bertel, provide free-standing stacks of containers arranged in rows to reduce the storage volume associated with storing such containers while still providing access to a particular container as needed. Access to a given container is made possible by providing a relatively complex hoisting mechanism that can be used to stack and remove a given container from the stack. However, the cost of such systems is prohibitive in many situations, and they have been commercialized primarily for the storage and handling of large shipping containers.

[0003] The concept of using a free-standing stack of containers and providing a mechanism for retrieving and storing a particular container has been further developed, as described, for example, in EP 0767113B to Cimcorp. EP '113 discloses a mechanism for removing multiple stacked containers using a robotic load handler in the form of a rectangular tube that is lowered around the stack of containers and configured to be able to grab a container at any level in the stack. In this way, several containers can be lifted from the stack at once. A movable tube can be used to move several stack containers from the top of one stack to the top of another stack, or to move containers from the stack to an external location and vice versa. Such a system may be particularly useful where all containers in a single stack contain the same product (known as a single product stack).

[0004] In the system described in EP '113, the height of the tube must be at least as high as the height of the largest stack of containers so that the tallest stack of containers can be extracted in a single motion. Thus, when used in enclosed spaces such as warehouses, the maximum height of the stack is limited by the need to accommodate the tubes of the load handler.

[0005] EP1037828B1 (Autostore) describes a system in which a stack of containers is arranged within a frame structure. A system of this type is illustrated diagrammatically in Figures 1 to 4 of the accompanying drawings. A robotic load handling device can be controllably moved around the stack on a system of tracks on the top surface of the stack.

[0006] A load handling device is described in UK Patent Application No. GB2520104A - Ocado Innovation Limited - in which each robotic load handler covers only one grid space, thus allowing a higher density of load handlers and therefore a higher throughput for a system of a given size.

[0007] In the known robotic picking systems mentioned above, a robotic load handling device is controllably moved around the top of the stack on a track system forming a grid. A given load handling device picks up a bin from the stack and a container is lifted containing the inventory items required to fulfil a customer order. The container is transported to a pick station where the required inventory items may be manually removed from the bin and placed in a shipping container. The shipping container, forming part of the customer order, is manually filled for timely dispatch. At the pick station, the items may also be picked by an industrial robot suitable for such operations, for example as described in UK Patent Application No. GB2524383B - Ocado Innovation Limited.

[0008] As shown in Figures 1 and 2, stackable storage containers known as bins 10 are stacked on top of one another to form a stack 12. The stacks 12 are arranged within a framework 14 in a warehouse or manufacturing environment. Figure 1 is a schematic perspective view of the framework 14, and Figure 2 is an overhead view showing a single stack 12 of bins 10 arranged within the framework 14. Each bin 10 typically holds multiple products or inventory items, and the inventory items within a bin 10 may be the same or may each be of a different product type depending on the application. Additionally, the bins 10 may be physically subdivided to accommodate multiple different inventory items.

[0009] The framework 14 includes a plurality of upright members 16 that support horizontal members 18, 20. A first set of parallel horizontal members 18 are disposed at right angles to a second set of parallel horizontal members 20 to form a plurality of horizontal lattice structures supported by the upright members 16. The members 16, 18, 20 are typically fabricated from metal. The bins 10 are stacked between the members 16, 18, 20 of the framework 14 such that the framework 14 guards against horizontal movement of the stack 12 of bins 10 and guides vertical movement of the bins 10.

[0010] The top level of the framework 14 includes rails 22 arranged in a grid pattern across the tops of the stacks 12. With further reference to Figures 3 and 4, the rails 22 support a plurality of robotic load handling devices 30. A first set 22a of parallel rails 22 guides movement of the load handling devices 30 in a first direction (X) across the top of the framework 14, and a second set 22b of parallel rails 22 is disposed orthogonally to the first set 22a and guides movement of the load handling devices 30 in a second direction (Y) orthogonal to the first direction. In this manner, the rails 22 enable movement of the load handling devices 30 in two dimensions in the XY plane, such that the load handling devices 30 can be moved to a position above any of the stacks 12.

[0011] Each load handling device 30 comprises a vehicle 32 arranged to move in the X and Y directions on the rails 22 of the framework 14 above the stack 12. A first set of wheels 34, consisting of a pair of wheels 34 at the front of the vehicle 32 and a pair of wheels 34 at the rear of the vehicle 32, are arranged to engage two adjacent rails of the first set 22a of rails 22. Similarly, a second set of wheels 36, consisting of a pair of wheels 36 on each side of the vehicle 32, are arranged to engage two adjacent rails of the second set 22b of rails 22. Each set of wheels 34, 36 can be raised and lowered so that either the first set of wheels 34 or the second set of wheels 36 are engaged with the respective set of rails 22a, 22b at any one time.

[0012] When the first set of wheels 34 engages the first set of rails 22a and the second set of wheels 36 is lifted off the rails 22, the wheels 34 can be driven by a drive mechanism (not shown) housed within the vehicle 32 to move the load handling device 30 in the X direction. To move the load handling device 30 in the Y direction, the first set of wheels 34 is lifted off the rails 22 and the second set of wheels 36 is lowered into engagement with the second set of rails 22b. The drive mechanism may then be used to drive the second set of wheels 36 to accomplish movement in the Y direction.

[0013] In this manner, one or more robotic load handling devices 30 can move around the top surfaces of the stacks 12 on the framework 14 as shown in Figure 4 under the control of a centralized control utility (not shown). Each robotic load handling device 30 is provided with lifting means 38 for lifting one or more bins 10 from the stack 12 to access the required products.

[0014] The body of the vehicle 32 includes a cavity 40 that is sized to hold the bin 10. The lifting means 38 includes a winch means and a bin gripper assembly 39. The lifting means lifts the bin 10 from the stack 12 into the cavity 40 in the body of the vehicle 32. In the cavity 40, when the bin 10 is fully lifted from the rail below, the load handling device can move laterally to a different location on the grid. Upon reaching the target location, e.g., another stack, an access point in a storage system, or a conveyor belt, the bin 10 can be lowered from the cavity and removed from the gripper assembly 39.

[0015] In this way, multiple products can be accessed from multiple locations in the grid and stack at any one time.

[0016] The above description describes a storage system in relation to, for example, food items.

[0017] FIG. 4 shows a typical storage system having a number of load handling devices 30 operating on a grid above the stacks 12 .

[0018] 1 and 4 show bins 10 in a stack 12 in a storage system. It will be appreciated that in any given storage system there may be many bins 10 and many different items may be stored in the bins 10 in the stack 12. Each bin 10 may contain a different category of inventory items within a single stack 12.

[0019] In one system, as described above and further in UK Patent Application No. GB2517264A - Ocado Innovation Limited, which is incorporated herein by reference, the storage system comprises a series of bins 10 which may further comprise delivery containers DT in which customer orders are contained, or which may further comprise bins 10 in which inventory items awaiting picking are contained. These various bins 10 and combinations thereof may be contained within the storage system and accessed by a robotic load handling device 30 as described above.

[0020] It will be appreciated that the automated or semi-automated storage and retrieval systems are not limited to systems targeted at food products. For example, the technology can be applied to shipping, baggage handling, vehicle parking, indoor or hydroponic greenhouses and agriculture, modular buildings, self-storage facilities, material handling, transportation switch yards, manufacturing facilities, pallet handling, parcel sorting, airport logistics (ULD), and general logistics, to name a few possible applications. It will be appreciated that different types of storage and retrieval systems have different technical requirements.

[0021] It is against this background that the present invention is conceived.

[0022] The present disclosure describes systems, methods, and devices for providing an efficient and economical alternative to conventional systems. For example, the present disclosure can be used to store and retrieve large and bulky items. At some scales, i.e., when very large containers are utilized, it may be impractical to operate a cube system. Summary of the Invention

[0023] Aspects of the invention are set out in the accompanying claims.

[0024] system A storage system is provided, comprising at least one storage floor comprising a track network based on a grid system, the track network comprising a first set of track members extending in a first (x) direction and a second set of track members extending in a second (y) direction, the second set of track members extending transversely to the first set of track members in a substantially horizontal plane, the track network comprising an access aisle and a storage aisle, the storage aisle comprising one or more storage locations for receiving storage containers and at least one load handling device operative on the track network for lifting and transporting the storage containers. The storage locations may comprise support means for supporting the storage containers.

[0025] The storage location is located above a storage floor or level. The storage container is positioned on a support means within the storage floor or level. The support means may include one or more stands, supports or brackets, optionally the support means may include at least two stands or supports or brackets. Typically the storage container is stored in the storage location.

[0026] The storage containers are moved around the system by load handling devices or bots. The load handling devices may be semi-automatic or fully automatic. The cradles, brackets or supports are sized and positioned such that the load handling devices can pass between them and travel on a network of trucks or tracks. Additionally, the cradles are of a height such that the unloaded load handling devices can pass under the storage containers when the storage containers are supported by the cradles.

[0027] The track network is typically arranged with a number of access aisles without racks and a number of storage aisles with racks providing locations for storage of containers. There may be a number of side aisles off the storage aisles to access further storage locations. A side aisle of a storage aisle is one or more storage locations deep. Typically, when the storage system is optimized for storage density, the side aisles are two to six storage locations deep. For storage systems optimized for fast and approximately uniform retrieval times, the side aisles may be one deep. The multiple storage aisles may be connected by access aisles located at each end of the storage aisle.

[0028] The truck network, and therefore the storage locations, are arranged on a grid system to efficiently utilize the available space and typically maximize the storage capacity of the system or facility. Each grid unit may be considered a "reservable location." A reservable location may be a single grid unit, or a reservable location may be a number of adjacent grid units, e.g., a length of a truck or a route. In some instances, a reservable truck length may be a single unit, and in other instances, several of the same unit trucks may be reservable independently of each other. A reservation of a reservable location may have a start time and an end time. In this manner, whether a grid unit is reserved or not changes over time. A reservable location may be reserved for a particular storage container and / or load handling device. Every location in the system may be reservable. Over time, each reservable location may have several non-overlapping reservations, which may be for the same or different load handling devices and / or storage containers. Reservations of reservable locations may be maintained in a reservable location table. It will be appreciated that the load handling device navigation system and controller may support reservable locations of variable length. At each variable length reservable location, there may be at most one position where a load handling device can change its direction of movement to an orthogonal direction on the track network. In this manner, the locations of the grid system may be managed by a control facility, which is described in more detail below.

[0029] Typically, the tracks comprise troughs, rails, guideways, or any other suitable structure for receiving or engaging the wheels of the load handling device. The troughs, rails, or guideways may be paired for each track path. The tracks provide a path for the load handling device. It will be understood that some grid spaces may be without tracks to accommodate building structural features such as columns extending through the building and floor. The track network may be comprised of any number of first and second members. The first and second track members are arranged substantially orthogonally according to a grid pattern. The floor is substantially flat and level, and the tracks are arranged in a substantially horizontal plane.

[0030] Each location in the system may comprise a single grid unit, or the locations may comprise an integer number of grid units. The tracks may be a single grid unit wide. Typically, each grid unit may include a track in the x direction and a track in the y direction. Typically, the storage locations and other features of the system may comprise a single grid unit.

[0031] When transported by the load handling device, the storage container is supported by a support pad positioned on the upper surface of the load handling device. The support pad can be raised and lowered by the load handling device so that the storage container can be lifted away from the cradles arranged along the path of the load handling device, so that the cradles do not impede the movement of the storage container. Typically, the load handling device moves with the support pad lowered for stability. Typically, when the load handling device arrives at a location adjacent to a destination location (such as a storage location), the load handling device raises the support pad. The load handling device then moves to a position to place the storage container. When the load handling device is in position between the cradles of the destination location, the support pad is lowered and the storage container is supported by a pair of cradles at each end. The load handling device can then continue to move from the storage location along the track network to perform another load handling operation. Typically, the load handling device moves between storage aisles on the same floor by using an access aisle.

[0032] The track network may comprise one or more temporary storage locations comprising support means for supporting storage containers. The track network may further comprise one or more of a charging bay, a passing lane, a siding, a lay-by, and / or a passing point.

[0033] The layout of the floor or track network typically includes additional features for efficient operation of the system. For example, an access aisle may be two pairs of tracks wide. The inner pair of tracks (e.g., closest to the storage aisle) provides a conceptual main route or highway for the traffic of load handling devices. The outer pair of tracks (e.g., furthest from the storage aisle) may provide locations for other features of the network.

[0034] For example, the evacuation may be for automatic recovery of a failed or damaged load handling device, or for an operator to access the load handling device, or for placing a failed load handling device awaiting removal to an on-site repair or maintenance area. Pass-through points may allow load handling devices traveling in the opposite direction on the same interior track route to pass through. Additionally, the track network may comprise locations for other auxiliary functions for the system to operate.

[0035] The charging locations or charging points for the load handling devices may include inductive charging pads located between the tracks that inductively transfer energy to the load handling devices via the interrelated charging pads on the underside of the load handling devices. Typically, the charging locations for the load handling devices may be located where the load handling devices tend to spend a period of time. For example, the charging locations may include a waiting location adjacent to a lift, a location at a container receiving station, a location at a container shipping station, a queue location for a container guide station where the load handling device waits until a receiving station position is available, a queue location for a container shipping station where the load handling device waits until a shipping station position is available, or even one or more locations along an access corridor to charge the load handling device while the load handling device waits for the next available lift car to move to another level. It will be appreciated that there may be at least one charging location on each storage floor.

[0036] Adjacent tracks may be sized to allow two load handling devices loaded with storage containers to pass over adjacent tracks with enough space for proper tolerances to avoid collisions.

[0037] The temporary storage location may be used for storage containers that have been temporarily removed from the side aisle to access storage containers deeper in the side aisle. In use, for example, a storage container located in an aisle that is several storage locations deep may be moved to the temporary storage location to access a storage container located several grid units away from the access aisle.

[0038] If the load handling device is carrying storage containers, these temporary storage locations may only be accessed when the load handling device's load pad is in a raised position to avoid collision with the cradle. Typically, temporary storage locations are not used in locations where the load handling device is expected to be passing through traffic.

[0039] There may be specific aisles specially configured to provide physically and environmentally controlled storage conditions, which may be temperature and humidity controlled.

[0040] There may be specific corridors with specific gas compositions, for example low oxygen and high nitrogen atmospheres to reduce the risk of fire. An entire floor of the storage facility may operate with low oxygen and high nitrogen atmospheres to reduce the risk of fire. The entire storage facility may operate with low oxygen and high nitrogen atmospheres to reduce the risk of fire.

[0041] The aisle may be subdivided into one or more chambers or galleries, each configured to provide different physically and environmentally controlled storage conditions, which may be temperature and humidity controlled.

[0042] The floor may be divided into chambers by a partition means having openings or hatches through which load handling devices can pass. The partition means may be provided with fire protection means and / or the partition means provides separation between user and robotic access within the system.

[0043] The partitioning means may comprise partition walls. The storage aisle may be subdivided, for example, into chambers or galleries. The partition walls may comprise climate-controlled doors. This may allow each gallery or chamber to have, for example, its own specific target ambient air temperature, its own target ambient air humidity.

[0044] The system may further comprise a flame detection system. The system may further comprise a fire suppression system including, for example, a sprinkler system. The system may further comprise a smoke detection system. The system may further comprise a heat detection system. Each of the fire safety systems may include a network connection to a control facility. Partition walls may provide an opportunity to contain and / or limit the spread of fire in high density storage areas.

[0045] The storage system may further comprise two or more vertically arranged floors, the floors interconnected by one or more lifts accessible from an access aisle for transporting load handling devices between the floors, the floors comprising at least one storage floor and, optionally, one or more sky lobby floors for transport between the lifts.

[0046] The storage system may be expanded to cover more than one floor. For example, the system may occupy several floors in a building. To achieve continuity between floors or levels, the load handling devices can move between different levels in specially designed lifts. The lifts can transport the load handling devices with or without storage containers on the support pads of the load handling devices.

[0047] In a multi-floor system, different floors may be reserved for different service levels: the floor with the shortest transit time to a storage system output station may be reserved for storage of containers that require the fastest access time, while the floor with the longest transit time to a storage system output station may be reserved for storage of containers that do not require the fastest access time or do not pay a premium for the fastest access time.

[0048] Some aisles may be constructed with side aisles the depth of a single storage location. These aisles may be reserved for storing containers requiring the fastest access times.

[0049] Each floor or story may be serviced by one or more lifts. Typically the lifts may be bi-directional, i.e., capable of moving up and down. The lifts may be positioned directly or indirectly to access the aisles. The floors or lift cars may have tracks that allow the load handling devices to move directly from the storage floor to the lifts. The lift cars may be sized to accommodate one load handling device loaded with storage containers, or the lift cars may be sized to accommodate two or more load handling devices transporting storage containers.

[0050] Typically there are at least two bi-directional lifts with access to each floor to provide resiliency in the event of a lift failing.

[0051] In some arrangements the lift may be double-decker with stacked lift cars capable of servicing adjacent floors simultaneously and carrying two load handling devices to generate a higher lift throughput. For a double-decker lift car, the two load handling devices may be clustered or positioned at different levels during the lift's travel, resulting in a higher average lift throughput.

[0052] Some levels or floors of a multi-floor system may include sky lobbies, and load handling devices may travel on truck paths between lift systems. In systems without sky lobbies, lifts may stop at each storage floor. In some systems, lifts may stop at selected floors or levels. For example, some lifts may only serve lower floors in the system, while others serve upper floors. Or, some lifts may be reserved for specific destinations. Typically, sky lobby arrangements may be found in high-rise buildings where a single lift system is not feasible due to the architectural limitations of high-rise buildings. For systems with one or more sky lobbies, lifts may provide access to blocks of adjacent floors. In some systems, there may be at least two sky lobby floors providing access to the same level in the building, providing resilience to the system in the event of a failure of a load handling device that blocks a reservable truck location at the entrance / exit of a lift car at a particular level.

[0053] For very tall storage facilities with many levels or floors, the vertical path between the lowest and the highest floors may require passage through several lifts or lift systems. Transfer from one lift system to another may be via a transfer passage in a sky lobby floor. The sky lobby floor may be a storage floor as well as a floor for transfer between lift systems. Or, the sky lobby floor may simply be a transfer floor.

[0054] It will be appreciated that the levels or floors of a storage system do not necessarily correspond to floors of the building in which the storage system is located. For example, several storage system floors may be located within a single floor warehouse type building and have structures within the space to create the storage system floors.

[0055] The storage system may further comprise one or more of a control facility, an environmental control facility means, a security system, a data collection means, a data communication means, and a communication system.

[0056] The environmental control facility may comprise a global environmental control system or an environmental control system for a storage floor or part of a floor. The control system may control the temperature and / or humidity of the air and / or the gas composition, for example the nitrogen content of the air.

[0057] The storage facility may include one or more maintenance areas on one or more floors. The maintenance areas may be accessible by the operator.

[0058] Maintenance areas may be located in spaces between partition or bulkhead walls. Such spaces may provide routes for cables and infrastructure for service feeds, such as communications, power, lighting, environmental sensing, video cameras, fire detection, and fire suppression. Partitioning means may include temporary barriers to provide safe areas for technicians to work or for evacuation.

[0059] Storage floors or aisles may be arranged alternately with maintenance areas. In other arrangements, the aisles may be arranged side-by-side or back-to-back, providing load handling devices for direct transfers between aisles on a track network (rather than via an access aisle), particularly when moving without carrying, for example, growing trays.

[0060] The maintenance area may include, for example, a cable passage suspended from the ceiling, which may be used in cases where the growing floor is not, in practice, interleaved with the maintenance level.

[0061] The storage system may further comprise one or more workstations, optionally each workstation comprising an RFID reader, scanner or camera for reading identification tags or labels on the storage containers.

[0062] One or more of the workstations may be suitable for an operator, or one or more of the workstations may be automated or semi-automated. In this manner, the storage system may be a Goods-to-man system. The storage containers may be transported to or through the workstations on the load handling device. The storage containers may remain on the load handling device while at the workstation, or the storage containers may be placed by the load handling device onto a pair or set of cradles at the workstation.

[0063] The workstations are for performing processes on the storage containers. The workstations in the system may include one or more of a container introduction workstation, a container dispatch workstation, a picking workstation for picking goods or items from a container and transferring them to another container or transferring items to a distribution container, and a workstation for returning empty storage containers to the container introduction.

[0064] One or more of the particular workstations may be combined into a single workstation. For example, a combined workstation may include a combined install and dispatch workstation, where different tasks or functions may be performed on the same workstation.

[0065] Each workstation may have the capability to read the identification tag or label of a storage container prior to processing the storage container. In this manner, the controller can verify that the storage container is being handled correctly at each stage and can take corrective action if the storage container is not being processed correctly at any stage.

[0066] Within the storage system, different types of workstations may be located on a single floor or within specific areas of a floor, or the workstations may be distributed across the growth floor and / or sky lobby floor.

[0067] The storage system may be provided with auxiliary functions.

[0068] It will be appreciated that the storage system may further comprise auxiliary spaces and auxiliary functions, for example, the storage system may be machine-to-person workstations, and load handling device service and maintenance stations.

[0069] The storage container may include a standard shipping container. Alternatively, the storage container may include a large area tray into which the items are placed. The storage container may include a unique identification tag or label.

[0070] Each storage container may have an RFID tag or marker, such as a barcode or QR code, that can be read by a scanner or camera providing a unique identification tag or label. In relation to each other, the load handling device or load handling device of the system may have an RFID reader or scanner or camera that can read the lugs or labels of the growth trays. Similarly, the workstations used to process the growth trays may have an RFID reader or scanner or camera that can read the lugs or labels of the growth trays. Thus, the load handling device has the ability to read the tag or label of the growth tray during the operation of picking the growth tray from the cradle. Similarly, each growth tray processing workstation has the ability to read the tag or label of the growth tray. Each growth tray processing workstation may read the tag or label of the growth tray before processing the growth tray. In this way, the controller can verify that the correct growth tray is being handled at each stage and may take corrective action, if necessary, if it is not the correct growth tray at any stage. Advantageously, the system may increase confidence in the integrity of the control and allow an audit record to be created.

[0071] Load Handling Devices A load handling device is provided for operating within a storage system, where a floor of the storage system may comprise a network of tracks based on a lattice system or a track network, the tracks comprising a first set of track members extending in a first (x) direction and a second set of track members extending in a second (y) direction, the second set of track members extending transversely to the first set of track members in a substantially horizontal plane, and the load handling device may comprise a first set of wheels for engaging the set of track members in the first direction and a second set of wheels for engaging the set of track members in the second direction, where the load handling device is drivable in the first or second direction to any location on the track network and may comprise a support pad for carrying a storage container.

[0072] The support pad may be raised and / or lowered in the vertical (z) direction.

[0073] Load handling devices are also known as bots, autonomous vehicles or semi-autonomous vehicles.

[0074] In this manner, the load handling device may be used to lift and transport the storage container along the network of tracks to any location within the storage system, such as a storage location or a workstation. The bot or load handling device may be capable of moving forward and reverse along the x- and y-tracks.

[0075] Typically, a storage container may be placed on a support means, such as a cradle, by a load handling device. When the load handling device carrying the storage container is in position, a support pad is lowered so that the cradle supports the storage container. The load handling device can then move away from its location along the track (without continuing to carry the storage container) and underneath the storage container to proceed with subsequent lifting and / or transport tasks.

[0076] To lift a storage container from a storage or other position with the support pad in the lowered position, the load handling device positions itself under the storage container and raises the support pad so that the load handling device supports the storage container and may transport the storage container to an alternative location.

[0077] The support pad or vertical lift mechanism may comprise an electro-mechanical mechanism. The vertical lift mechanism may comprise an electro-hydraulic generator and one or more hydraulic rams. In the event of failure or leakage, a protective enclosure may be used to prevent hydraulic fluid from contaminating the storage system. The electro-hydraulic generator and ram components may be commercially available components.

[0078] The first set of wheels and / or the second set of wheels may comprise two or more wheels on each side.The load handling device may comprise suspension means for one or more of the wheels.

[0079] The floor of the storage facility may be substantially flat such that the tracks are in a substantially horizontal plane, although it will be appreciated that it may not be cost effective to ensure that the floor is perfectly flat. In any event, the floor may have a step change in level or may not be flat. The track path may be defined by navigation means of the load handling device interacting with the control facility, or the track path may be defined by grooves or rails, as described elsewhere herein.

[0080] By locating three wheels on each side of the load handling device, the device can withstand gradual changes in track height - either due to intentional changes in track height or due to imperfections in the construction of the facility floor. When moving over a step change on the first set of wheels or the second set of wheels, the load handling device rotates as the center of gravity of the load handling device passes over the level discontinuity or step. In this way, the load handling device typically keeps at least four of its wheels in contact with the surface or track.

[0081] Each set of wheels may be positioned on a respective side with one wheel substantially in the center of the side, thereby enabling the load handling device to remain substantially stable or to withstand level changes or bumps in the truck. For example, if the set of wheels includes three wheels, the middle wheel may be positioned substantially in the center of the side.

[0082] Furthermore, by providing suspension to the wheels, the load handling device may be more tolerant to track changes as the load handling device moves along a path. All wheels may be provided with suspension means. Track changes may include small changes in direction and step changes.

[0083] The wheels may be aligned in a first (x) direction or may be aligned in a second (y) direction, and the wheels comprise caster wheels.

[0084] The wheels may be aligned in the x-axis and y-axis directions of the load handling device corresponding to the orientation of the track member layout in the grid-based network of tracks. If the wheels are caster wheels, i.e., can be slightly deflected by a relatively small angle about the mounting direction, the load handling device may be more tolerant to misalignment between track members or sections of tracks. The degree of caster may be limited. The caster function may be enabled by a spring arrangement. The wheels may be spring loaded to align with the axis of the load handling device. The wheels may have a mechanically limited flexibility to help the load handling device negotiate imperfections in the track.

[0085] The above features are designed and engineered to provide less restrictive requirements for step changes, gradients, and alignment of tracks on two-wheel vehicles, allowing for less restrictive construction tolerances, which allows for older warehouse buildings to be reused and reduces tolerances for new building construction.

[0086] It will be appreciated that the load handling device may include a direction change mechanism for switching the engagement of the x-direction wheels and the y-direction wheels in engagement with the truck.

[0087] The direction change mechanism and the storage container lift mechanism may be the same mechanism.

[0088] The x-direction wheels may be mounted on a sub-chassis which is supported and moves vertically within retaining flanges at each end. Vertical movement of the sub-chassis in the retaining flanges may be made to have low friction by the use of roller bearings, needle bearings, slide bearings, or bearings. In one arrangement, vertical movement of the sub-chassis may be achieved using a two stage hydraulic ram. It will be appreciated that the hydraulic ram may include additional stages. The y-direction wheels may be similarly mounted. It will be appreciated that it may be advantageous to mount the y-direction wheels directly to the main chassis with a suspension unit and allow the x-direction wheels to move relative to the main chassis.

[0089] In an alternative arrangement, vertical movement of the sub-chassis may be accomplished by a toothed rack in the retaining flange. The toothed rack may be driven by a toothed pinion drive wheel by an electric motor. The wheel sub-chassis device may include a toothed rack assembly at each end.

[0090] Each sub-chassis may be equipped with one or more sensors for detecting and reporting relative vertical displacement between the sub-chassis and the support pad or storage container carrying chassis.

[0091] The load handling device may further include a rechargeable battery and / or a supercapacitor for powering the drive motor, the rechargeable battery and / or supercapacitor being charged through an inductive charging pad positioned on the underside of the load handling device.

[0092] The load handling device may be driven by an on-board motor powered by a rechargeable battery. In an alternative arrangement, the on-board motor may be powered by a supercapacitor. Or in some arrangements, the load handling device may include both a rechargeable battery and a supercapacitor. It will be appreciated that the supercapacitor charge (and discharge) time may be much faster compared to the battery recharge time. Thus, if both a rechargeable battery and a supercapacitor are used, the load handling device may benefit from a quick increase or replenishment of power from the supercapacitor and a more sustained power from the rechargeable battery.

[0093] The charging locations may be conveniently located where the load handling devices tend to remain over a period of time, but may also be anywhere on the track network. Typically, energy providing inductive pads are located between the track rails at specific grid locations.

[0094] One or more of the wheels may be drivable.

[0095] All wheels of the first set of wheels and the second set of wheels may be drivable.

[0096] Each of the wheels of the set of wheels may be driven. In this way, if one of the wheels loses contact with the track surface, the load handling device is still driven by the remaining wheels. Additionally, this can help maintain the stability of the load handling device on uneven surfaces.

[0097] One or more of the first set of wheels and the second set of wheels are lockable by a locking means.

[0098] The locking means may comprise an electromechanical lock for locking the drive motor for x- and / or y-movement. The motor may be locked to prevent movement of the wheels and the load handling device when the load handling device is in a parking position, e.g. when lifting or placing a storage container, moving with a lift truck, or in a charging location. The electromechanical lock may have a release means. For example, the release means may be a switch operable by the control system or a technician. When the lock is not applied, the wheels are free to rotate. In this way, in case of a load handling device failure, the lock can be released and the load handling device can simply be pushed or pulled to a maintenance area. The lock may be releasable by a recovery device. Once the load handling device is free to move, the recovery device can further push or pull the failed load handling device. The recovery device can move the failed load handling device to a maintenance area so that the technician is not exposed to danger when working in other areas of the system.

[0099] The load handling device may further comprise an RFID reader, scanner, and / or camera for reading the identification tag or label.

[0100] The load handling device may have the ability to read an identification tag. For example, during operation, the load handling device may identify a particular storage container, or the load handling device may identify a particular location in the system where the tag is located in or along a truck, or at a workstation.

[0101] The load handling device and supported storage container have a footprint that occupies only a single grid space within the storage system.

[0102] A single grid space or grid unit may be a single reservable location. In this manner, a load handling device carrying a storage container may traverse any truck route with virtually no risk of collision (assuming the load handling device is centered at a grid location and the storage container is properly centered on the load handling device's support pad).

[0103] The load handling device may further comprise navigation means for monitoring and controlling movement along the track network. The load handling device may further comprise communication means for receiving commands from and transmitting data to a central control facility. The load handling device may further comprise a proximity sensor.

[0104] The load handling device may have a software map in a non-volatile memory for each floor of the storage system. The software map may contain information about each of the reservable track locations, including physical dimensions, identification codes of the fiducial markers, positions of the fiducial markers, physical attributes of the reservable track locations, such as the presence of a cradle, and the topology of the track path connections between the reservable track locations. The software map may enable the device controller to calculate trajectory parameters for each segment of the path provided by the (central) control facility.

[0105] The device controller may control servo mechanisms and electric motors that select wheel states, support pad states, and move the load handling device along the track. The load handling device may acknowledge all commands received with a response message sent to the controller.

[0106] At least some navigation and other control commands for the load handling devices are provided to the load handling devices by a (central) control facility.

[0107] The (central) control facility may provide instructions for routes for the load handling devices to travel along and across the floors. Routes are planned by a route planning module. Segments of the route at specific times may be reserved and issued as instructions to the load handling devices and recorded prior to the start time. Route instructions for traversing individual segments of the route or tracks are issued to the load handling devices and the clearance module of the control facility.

[0108] It will be appreciated that the path planning module plans a collision risk free path before the load handling device moves. Meanwhile, the path clearance module monitors position, speed and status reports from all load handling devices operating in the storage system to ensure that the intended planned path for a particular load handling device remains collision risk free. The planned path may be compromised and at risk of collision or another form of accident due to load handling device failure, degradation of load handling device performance, and / or communication failure to or from the load handling device. If a collision risk is identified, the path clearance module may notify the path planning module so that a new collision risk free path may be planned.

[0109] The load handling device itself may further comprise a device controller capable of receiving and acknowledging commands from the central control facility. Additionally, the device controller may use output from the load handling device sensing means for feedback for use in controlling movement of the load handling device and for feedback or reports to provide to the central control facility, particularly the clearance module.

[0110] It will be appreciated that the load handling device may be equipped with sensing means as described above. The sensors may be one or more of a laser scanner, scanner or camera for detecting a reference marker in proximity to the track, a depth sensor or camera for detecting the intersection of track members, a sensor for monitoring and reporting the rotation of one or more of the wheels, and a non-driven wheel detector for monitoring and reporting the rotation of the wheels. It will be appreciated that other sensors and data collectors may be provided for monitoring the status of the load handling device. The load handling device may send a position and status report to a central controller (control facility) each time it passes a reference marker.

[0111] The load handling device may further comprise a proximity sensor, preferably on each side of the device, to warn of an unexpected collision risk. In such a situation, the temperature rise may trigger an emergency stop. Examples of unexpected items that pose a collision risk include other load handling devices directly in the intended path, storage containers accidentally dropped onto the intended path, collision barriers marking the end of the path and encountered due to navigation or mapping errors, cradles encountered due to navigation or mapping errors, and (human) personnel working within the facility.

[0112] The system may further include a survey bot for collecting data and monitoring the status of the system. The movement and control of the survey bot may be similar to the movement and control of the load handling device. The survey bot may move along the growing aisle and survey each storage container. For example, the survey bot may be a vehicle similar to the load handling device but without the support pads and with a sensor pack.

[0113] Other types of bots or mobile devices are envisioned to operate within the system and cooperate with the described devices, for example task specific devices.

[0114] Control Equipment A control facility is provided for controlling and operating the storage system as described above. The control facility comprises one or more of an environmental control module, a manager module, a task planner, a bot path planning module, a bot path clearance module, a communications module, a lift task planner, a bot charge state manager, a data storage and persistence module, a long term data storage module for providing data to machine learning algorithms, a recovery, repair and / or maintenance manager module for modifying plans and schedules to facilitate recovery, repair and maintenance operations, and a machine learning and / or artificial intelligence module designed to fine tune the system based on its previous operating history.

[0115] One or more of the independent air temperature for one or more storage aisles, chambers, or floors, independent air humidity for one or more aisles, chambers, or floors, independent air flow for one or more aisles, chambers, or growing floors may be controllable by a control device and / or the control facility may perform the planning and / or management, the control facility may ensure that the correct storage containers are handled at each stage, and the control facility may create an audit record of each operation.

[0116] The control facility may comprise one or more computers. The one or more computers may be physically co-located with the agricultural system, or the one or more computers may be located remotely from the agricultural system. The control facility may be accessed via the Internet and / or may be based on cloud services. A central control facility may be responsible for managing the agricultural system. Individual components of the system, such as load handling devices or bots, management stations, etc., may comprise local or individual control facilities that communicate with the central control facility. It will be appreciated that the central control facility may coordinate the control systems of the individual components in the agricultural system. The individual components in the agricultural system may operate, at least to some extent, autonomously or semi-autonomously.

[0117] The one or more computers may comprise one or more memories and one or more processors, and the one or more memories include program instructions executable by the one or more computers to implement a control facility for the storage facility. The system or control facility may comprise multiple processing components (modules), each configured to execute a respective portion of a control system configured to have at least one module.

[0118] The control facility may include any suitable architecture. The software modules of the control facility may be implemented to run on many computers located at several different physical locations within the system, or located remotely from the system, for example via a cloud-based system. Each software module may be responsible for maintaining its own data structures and persisting those data structures to a non-volatile storage medium or device.

[0119] Data may be exposed and transferred between modules by any suitable means, including, for example, calls to interfaces designed to exchange data and messaging protocols designed to exchange data.

[0120] The software modules may be executed in parallel or serially.

[0121] A state change in the software may affect downstream modules. A state change may occur immediately upon notification of a previous module. Typically, a state change may result in a downstream entry of the task in a task queue, or completion of the task may result in a state change.

[0122] The environmental control module can control the environment within the storage system. The environmental control can be global / facility-wide or the environmental control can be localized to a storage aisle, a section of a storage aisle, or a chamber. The environmental control module can control temperature and airflow.

[0123] A system planner or manager module identifies demand for particular storage containers in particular time slots so that groups of interchangeable storage containers can be created and assigned to adjacent storage locations in the side aisle. This can be a very efficient optimization since temporary relocation of storage containers is not required to access members of an interchangeable group since storage containers closest to the center of the aisle can be accessed first.

[0124] The task planner module evaluates the expected time of a storage container in the storage location before retrieval and runs an optimization algorithm to place the storage container with the shortest storage time in the aisle closest to the dispatch workstation on the floor with the harvesting equipment, thus minimizing the total lift service time required and therefore the number of trips required.

[0125] The task planner module processes and builds plans. Plans created by the task planner are continuously revised as the demand forecast evolves. The task planner can modify the plan to meet the demand in a particular time slot. Tasks are created and scheduled with a task planning horizon time limit.

[0126] The storage system bot or the load handling device path planning module can reserve overshoot reservable track locations for the estimated settling time of the load handling device lateral control system for each segment of the path to plan the route the load handling device should take. If a segment of the path is defined as the bookable location where the load handling device starts moving to the next bookable location where the load handling device is planned to stop, this includes pauses as the load handling device changes wheel configuration between x and y or between y and x.

[0127] The path planning module reserves reservable locations along the track for a particular storage container movement task. A separate instance of the load handling device path planning module may run for each floor. The load handling device path planning module creates a reservation table for all reservable locations across floors. Each reservable location can have many reservations for different load handling devices at different times. Since collisions between large load handling devices can require very long recovery procedures, the load handling device path planning module can reserve overshoot reservable locations for estimated settling times of the load handling device's lateral control systems to further minimize the risk of collisions between the load handling devices. The load handling device path planning module identifies and evaluates these potential routes as part of its default behavior. In some examples, if the load handling device is not carrying a storage container, it may be possible to plan a route under the storage location.

[0128] The load handling device or bot path clearance module creates a record of occupancy of each bookable location by the load handling device to ensure that the planned route to be followed by the load handling device is clear, and creates a record of the bookable locations that the load handling device has been given clearance to enter as it crosses each bookable location on their planned route between picking up the storage container and placing the storage container. Typically, the load handling device reports its position entering the bookable location, its position centered at the bookable location, and its position exiting the bookable location. The load handling device clearance module is necessary to prevent collisions between load handling devices as a result of electromechanical failure of one or both load handling devices, failure of communication with one or both load handling devices, failure of the load handling device to maintain an expected kinematic and physical profile.

[0129] The load handling device selection and path planning module may be responsible for selecting available bots to perform lifting and / or transport tasks.

[0130] The communication module may be responsible for communication between the other modules and the manager. Each component of the storage facility may be equipped with a communication module. Each load handling device or bot may be equipped with a communication module. Each lift may be equipped with a communication module. Each workstation may be equipped with a communication module.

[0131] The lift task planner module generates a sequence of lift car stops. In a preferred embodiment, the lift task planner module selects lift operations to maintain the sequence of load handling device movements in the priority order determined by the task planner module, but whenever a queue forms, the lift task planner module switches pick-up and drop-off plans to maximize lift throughput. In the case of a double-decker lift car, this means delaying certain pick-ups in order to accommodate simultaneous pick-up and drop-off operations at adjacent floors.

[0132] The Recovery, Repair, and Maintenance Manager module automatically triages system failures including but not limited to: 1. Load handling device failure: Typically, the module sets a flag in the data to designate that the bookable location occupied by the failed load handling device is excluded, sets a flag in the data to designate that any inaccessible storage containers are inaccessible, and any failed load handling device is task-unavailable, i.e., not suitable to be assigned a task. The module calls on the path planning module to run, whose algorithms seek and plan alternative routes that avoid the newly excluded bookable location. Any tasks that are not plannable due to multiple failures are flagged to a human administrator who can choose to proceed with a maintenance and recovery mission. 2. Lift failure, typically the module sets a flag in the data to designate the lift as out of service, sets a flag in the data to designate that any stuck load handling devices are not taskable, and any inaccessible storage containers (on the stuck load handling devices) are flagged as inaccessible. The module requests the lift task planner module to re-plan all outstanding lift tasks.

[0133] The recovery, repair, and maintenance manager module can also be used to configure the storage facility for human recovery, human repair, and human maintenance operations. For example, manual recovery of a failed bot or load handling device may be accomplished with all load handling devices on the floor either safety stopped or moved to another floor, and then a safety barrier is placed across the tracks to physically prevent the load handling devices from colliding with humans. The recovery, repair, and maintenance manager module also sets a flag in the data to exclude all quarantined tracks so that normal production can resume on the non-quarantined sections of the floor. Once recovery is complete, all load handling devices on the floor are stopped or moved to another floor. The physical safety barriers are removed and the flags set in the data to exclude all isolated tracks are cleared. The load handling device path planning module can then use all non-excluded bookable locations when planning the paths of the load handling devices once operation of the load handling devices resumes on the floor.

[0134] The machine learning and / or artificial intelligence module is designed to improve planning and productivity and fine-tune the system based on its previous operating history. The module may use machine learning and artificial intelligence techniques in at least the following ways: 1. Long-term data on the movements of load handling devices is analyzed and aggregated across different classes (models) of load handling devices to refine the parameters used to define the physical models used in route planning. 2. Identification of possible load handling device routes on the floor and optimization of the selected route. 3. Long-term data of rift movement is analysed and aggregated across different classes (models) of rifts to refine the parameters used to define the physical models used in rift planning.

[0135] The machine learning and / or artificial intelligence module may use the following artificial intelligence and machine learning techniques, including, but not limited to: 1. Machine Learning 2. Neural Networks 3. Machine Learning (General) 4. Supervised learning 5. Probabilistic Graphical Models 6. Support Vector Machines 7. Bio-inspired approaches (including but not limited to Ant Colony Optimization) 8. Classification and Regression Trees 9. Deep Learning 10. Learning the rules 11. Unsupervised learning 12. Reinforcement Learning 13. Instance-Based Learning 14. Latent expression 15. Multitask Learning 16. Logic and Relational Learning 17. Logic Programming 18. Expert Systems 19. Description Logic 20. Logic Programming (General) 21. Fuzzy Logic 2 22. Ontology Engineering 23. Probabilistic Reasoning

[0136] It will be appreciated that the trucks and load handling devices are positioned such that when a load handling device is positioned at a reference marker that marks the notional "centre" of a bookable location, there is no risk of collision with other load handling devices, whether the load handling device is stationary or moving at an adjacent location.

[0137] It will be appreciated that alignment of the load handling device for orthogonal turnarounds on the grid-based track network is achieved using a laser scanner, scanner, or camera on the load handling device and fiducial markers proximate the tracks that mark the position of the intersection of the orthogonal tracks at the bookable location. This arrangement may provide precise positioning of the wheels and tracks of the load handling device in the orthogonal direction.

[0138] It will be appreciated that alignment of the load handling device within the storage location is achieved using a scanner, laser scanner or camera on the load handling device and a fiducial marker adjacent to the truck that marks the notional "center" point of the bookable location. This provides precise positioning of the storage container relative to the cradle.

[0139] A cargo handling device navigation system for tracking and controlling movement along a cartesian or grid-based track structure is accomplished by using sensor information.

[0140] A detailed map of each floor is downloaded to each load handling device when it is used in the load handling device or operation of the load handling device within a facility. The data associated with the map provides the motion control system of the load handling device with sufficient data to calculate its trajectory and control its movement along the trajectory. Data included with the map includes, but is not limited to, the physical dimensions of the bookable location, the position of reference markers on the bookable location, and the connections between the bookable location and any adjacent bookable locations.

[0141] Commands for the load handling device to move are generated by a load handling device path clearance module of the controller and transmitted to / from the load handling device by a communication module of the controller. The instructions for the load handling device to move have a start time for the move and are transmitted to the load handling device prior to the start time. The load handling device may send a confirmation that the command was received. This protocol allows the move command to be sent several times as necessary, adding resilience to the communications, since 100% message delivery is not guaranteed or expected.

[0142] Alignment of the load handling device for orthogonal direction changes can be accomplished using a laser scanner, scanner, or camera on the load handling device and a fiducial marker proximate to the track marking point, allowing the wheels of the load handling device to be accurately positioned orthogonally relative to the track. For bookable locations where orthogonal changes are not permitted, the fiducial marker may be placed at a notional center point of the bookable location.

[0143] Alignment of the load handling device within the storage location may be accomplished using a scanner, laser scanner, or camera on the load handling device and a fiducial marker adjacent to the truck that marks the center point of the bookable location. This provides precise positioning of the storage container relative to the cradle.

[0144] use A method of using the storage system is provided, the method may include one or more of the steps of transporting and placing a storage container using a load handling device, placing the storage container at a storage location, retrieving the storage container from the storage location, placing the storage container in a storage aisle, and optionally controlling the environment in the storage aisle according to requirements.

[0145] When the load handling device is instructed by the central control facility to place a storage container on a pair of cradles at a storage location, the load handling device moves along the access aisle while carrying the storage container until it is adjacent to the desired storage location. With the support pads raised, the load handling device moves from the storage aisle into the side aisle such that the storage container on the support pads is above the cradles in the side aisle. It will be understood that the route to the storage aisle is calculated or planned by the control facility to avoid the storage location where the storage container is resting on the cradle. Typically, the load handling device may be instructed to place the storage container at the storage location so as not to block access to other available storage locations in the storage aisle. When positioned at the instructed location, the load handling device lowers the support pads, leaving the storage container supported by the cradles at the storage location. The load handling device then moves in the opposite direction, or via another instructed route, back to the access aisle.

[0146] When the load handling device is instructed by the central control facility to retrieve a storage container on a pair of cradles from a storage location, the load handling device moves along the access aisle until it is adjacent to a side aisle containing a storage location that contains the particular storage container. With the support pads lowered, the load handling device moves into the side aisle until the support pads are positioned below the target storage container. The load handling device then raises the support pads, lifting the storage container above the cradles. Once the storage container is delivered, the load handling device moves back through the storage area to the access aisle with the support pads in the raised position to avoid collision with the cradles. Once on the access aisle track, the load handling device may lower the support pads before navigating to its next destination.

[0147] It will be appreciated that if the central control system knows that there are multiple identical storage containers for the same item, the control facility can take advantage of the fungible nature of a group of storage containers and place the fungible storage containers in the same storage aisle. When any of the storage containers in the fungible group are needed, the controller planning module selects the storage container in the fungible group that is closest to the access aisle. That is, the control facility selects the storage container that can be accessed without temporarily relocating other storage containers in the storage aisle.

[0148] The number of load handling devices required by a system may be determined by the number of storage container movements rather than the number of aisles and / or storage locations, or the number of floors.

[0149] It will be understood that the storage containers are not stackable, and therefore the storage and retrieval system can accommodate containers that are not stackable or that have tops of variable heights or uneven upper surfaces.

[0150] Thus, the present invention addresses some of the problems of the prior art and provides a system, method and device for an item storage and retrieval system.

[0151] Integration with other systems The storage and retrieval system and the growing facility may be integrated with other automated systems. Integration may include: A conveyor that transports totes or containers containing searched or picked items to or toward the interior of mechanical processing equipment in a grocery store customer fulfillment center. In some arrangements, the dispatch workstation may be designed to be compatible with the tote and particularly item-interior mechanical processing equipment and systems used within an automated grocery store customer fulfillment center. Autonomous airborne vehicles or drones transporting the totes · Autonomous ground vehicles or autonomous guided vehicles transporting totes Any form of human-operated cargo vehicle transporting totes Any form of magnetic levitation transport system that transports totes Any form of integration between the order management and order forecasting system of the automated grocery store customer fulfillment center and the planner / manager module of the storage system, particularly where such integration is used to ensure product availability to the automated grocery store customer fulfillment center at specific time slots.

[0152] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals are used to refer to like features, and in which: [Brief description of the drawings]

[0153] [Figure 1] FIG. 1 is a representative diagram of a prior art storage system. [Diagram 2] FIG. 2 is a representative diagram of a prior art storage system track layout. [Figure 3a] FIG. 3a is a representative diagram of a prior art storage system load handling device. [Figure 3b] FIG. 3b is a representative diagram of a prior art storage system load handling device having a storage container. [Figure 3c] FIG. 3c is a representative diagram of a prior art storage system load handling device having a storage container. [Figure 4] FIG. 4 is a representative diagram of a prior art storage system having load handling devices on a grid above the storage. [Diagram 5] FIG. 5 illustrates a plan view of the storage facility. [Figure 6] FIG. 6 illustrates a portion of the storage floor shown in FIG. [Figure 7] FIG. 7 illustrates a portion of the storage floor shown in FIG. [Figure 8a]FIG. 8a illustrates a plan view of the long side, or yz side, of a load handling device with storage containers resting on lift pads. [Figure 8b] FIG. 8b illustrates a plan view of the long side, or yz side, of the load handling device with storage containers resting on lift pads. [Figure 8c] FIG. 8c illustrates a plan view of the long side, or yz side, of the load handling device with storage containers resting on lift pads. [Figure 9a] FIG. 9a illustrates a short side or xz side elevational view of the load handling device without the storage container and detailing the lift pads. [Figure 9b] FIG. 9b illustrates a short side or xz side elevational view of the load handling device without the storage container and detailing the lift pads. [Figure 9c] FIG. 9c illustrates a short side, or xz side, elevational view of the load handling device without the storage container and detailing the lift pads. [Figure 10] FIG. 10 illustrates an elevational view of the short side, or xz side, of the sub-chassis of the load handling device with the retention flange removed. [Figure 11a] FIG. 11a illustrates a long side or yz side elevational view of the load handling device. [Figure 11b] FIG. 11b illustrates a long side or yz side elevational view of the load handling device. [Figure 11c] FIG. 11c illustrates a long side or yz side elevational view of the load handling device. [Figure 12] FIG. 12 illustrates an underside, xy, plan view of the load handling device. [Figure 13] FIG. 13 is a schematic diagram of the controller of the storage system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0154] The present invention may form part of a larger system. It is to be understood that the systems, methods, and devices described herein are merely exemplary, and that other combinations and configurations of the described apparatus and equipment are contemplated by the inventors of the present disclosure without departing from the scope of the invention as described herein.

[0155] As mentioned above, Figures 1 to 4 are representative diagrams of prior art storage systems.

[0156] The storage system, load handling device, storage locations, method of use and control facilities of the present invention are illustrated in the remaining figures.

[0157] Figures 5 to 7 show schematic diagrams of a storage floor. The storage floor is divided into a grid of units, each unit having a designated function. Aisles 2 are disposed across the width and length of the storage floor. Typically, an access aisle 2 is two units wide and is disposed across each end of the storage floor as shown in Figure 1. Between the ends, the access aisles 2 are joined by storage aisles 2 which run perpendicular to the access aisles 2 and along the length of the storage floor. The storage aisles 2 are typically one unit wide. Adjacent to the storage aisles 2 are storage locations 1. The storage locations 1 may be accessed by load handling devices from either the access aisles 2 or the storage aisles 2.

[0158] As mentioned above, each storage location 1 is provided with a cradle for supporting storage containers. When the load handling device is not transporting storage containers, it can move in the x- and y-directions via any accessible route to any storage floor aisle or storage location. However, the load handling device can only move in one direction (x) through the storage location, and any attempt to traverse the storage location in the orthogonal direction may result in a collision between the load handling device and the support cradle.

[0159] As illustrated in Figure 5, maintenance areas 3 are located through the center of the area of ​​the designated storage locations 1 of the floor. Additionally, maintenance areas 3 are located along the long sides of the floor and in several unit locations along the short sides of the storage floor. The short sides of the storage floor also provide grid unit locations for evacuation, temporary storage, lift entry positions, lift exit positions, lift shafts, and charging points. These maintenance areas 3 are not accessible by load handling devices and are not used for repairs of load handling devices.

[0160] 6 and 7 show in greater detail a portion of the storage floor as shown in FIG.

[0161] FIG. 6 illustrates the end of a storage floor with two lifts. As shown, the last row of the storage floor comprises two lift shafts 8. Adjacent to each lift shaft 8, on a first side, there is a lift entry position 6 and a lift exit position 7. The lift entry 6 and lift exit 7 are kept clear to allow load handling devices to enter and exit the storage floor for transport to other floors in the system. Between the lift areas there is an additional maintenance area 3. The rest of the unit locations along the last row of the storage floor alternate between evacuation 4 and temporary storage locations 5 that may be used during operation of the system. Typically, the evacuation 4 is used to allow load handling devices with unloaded or loaded storage containers to pass when the aisle is congested. The evacuation 4 may also be used to temporarily position a failed load handling device. The temporary storage locations 5 typically comprise a pair of cradles. In this way, storage containers may be temporarily placed on the cradles while awaiting further transport to other locations. It will be appreciated that the temporary storage location 5 is located relatively close to the lift shaft 8 such that it may be used as a waiting area for transport between floors in the system. The temporary storage location 5 may be used while the load handling devices complete other tasks. Conveniently, as illustrated in Figures 3 to 5, the temporary storage location 5 is located adjacent to an access aisle that may be used primarily for transport.

[0162] Figure 7 illustrates an opposite end corner of the storage floor of Figure 3 relative to Figure 4. As with the first end, for most of the end row, the grid unit locations alternate between a retract 4 and a temporary storage location 5. Additionally, the final row includes a maintenance area 3 and a charging point location 9. The charging point location 9 is used to recharge the power resources of the load handling devices. Conveniently, the charging point 9, the retract 4 and the temporary storage location 5 are located adjacent to the access aisle 2.

[0163] It will be understood that the particular layout of the storage floor may be adapted to the building in which the storage floor is located. The use of different types of proportions and unit grid locations may be adjusted according to availability and need. Furthermore, it will be understood that other layouts of the storage floor are envisioned to provide an efficiently operating system. The exact layout will depend on the total capacity required for the storage system, as well as the size and shape of the building. Some sections of the storage floor may be divided by bulkheads and control doors (not shown).

[0164] It will be appreciated that global or facility-wide environmental control facilities may be located at the end of an aisle, above the floor at the ceiling, or in a maintenance area.

[0165] 8-12 illustrate a load handling device 301 for use in the storage system. The load handling device 301 is used to lift and place the storage containers 200 at locations within the system. Additionally, the load handling device 301 is used to transport the storage containers 200 between locations.

[0166] Figure 8 illustrates plan views of the long side, or yz side, of a load handling device with storage containers resting on lift pads in various configurations. In Figure 8a, the y-direction wheels 303 are deployed and the x-direction wheels are held in a raised position for forward and reverse movement in the y direction. Typically, the load handling device passes in the y direction in the configuration shown in Figure 8a.

[0167] In Figure 8b, the x-direction wheels 307 are deployed and the y-direction wheels are held in a raised position for forward and reverse movement in the x-direction. Typically, the load handling device moves in the x-direction in the configuration shown in Figure 8b. The storage container support pads 308 are slightly elevated in the configuration shown in Figure 8b compared to the configuration shown in Figure 8a, but the bottom of the storage container 200 is still below the top of the platform when transported.

[0168] In this manner, when transporting the storage container 200, the load handling device may travel along any unobstructed path along the track network 306 - typically an access corridor that does not have a rack. For example, the storage container 200 may be left at a location that has a rack, such as a temporary storage location or a storage location, or the storage container 200 may be removed and transported to a new location.

[0169] When the load handling device is in transport without carrying or supporting the storage container 200, the load handling device may travel along any route along the track network 306, possibly underneath the storage container mounted on a cradle.

[0170] Figure 8c shows the load handling device 301 of Figures 8a and 8b between a pair of cradles 311. In this configuration, the support pads 310 and storage containers 200 are raised so that the bottom of the storage containers 200 is above the top of the cradles 311. In the configuration shown in Figure 8c, the load handling device 301 can lower the storage containers 200 onto the cradles 311 before moving to a next location or moving to a next job. How the support pads 310 move from the lowered and raised positions is described in more detail below in conjunction with Figure 9.

[0171] Figure 9 illustrates a short side, or xz side, elevation view of the load handling device 301 without the storage container 200, showing the lift pads 310 and mechanisms in more detail. Figure 10 illustrates a short side, or xz side, elevation view of the load handling device with the moving sub-chassis removed. Figure 11 illustrates a long side, or yz side, elevation view of an alternative load handling device design in which lifting of the load (tray) support pads to clear the pedestal is accomplished using a third electric or hydraulic ram (305) that is independent of the two redirection mechanism rams. Figure 12 illustrates an underside, xy plan view of the load handling device.

[0172] As shown in Figure 9a, the ram mount 327 is attached to the load handling device chassis. The ram 331 shown comprises a first stage 329 and a second stage 330 nested within the first stage 329. It will be appreciated that the ram 331 is of the telescopic type. The upper end of the second stage 330 is attached to the sub-chassis 312. In this manner, the sub-chassis 312 can move up and down with the ram 331. The sub-chassis 312 is housed within retention flanges 317, 323 and guided by needle or roller bearings 324, as shown in Figures 9 and 10.

[0173] In Figure 9a, the ram 331 is fully compressed or nested, the wheels 307 are in their x-direction drive position, and the support pad 310 is at its maximum height. In Figure 9b, the ram 331 is partially extended or raised, the wheels 307 are in their drive position, and the support pad 310 is at its minimum height for x-direction drive. In Figure 9c, the ram 331 is fully extended and the wheels 307 are in their raised position (for y-direction drive by the wheels 303). In this way, the same mechanism is used to raise and lower the support pad 310 and control the x and y directions of the load handling device 301.

[0174] One or more displacement sensors 304, 326 may monitor the distance traveled by the load handling device in the y and x directions, respectively.

[0175] FIG. 10 illustrates a side elevation view of the short side, or xz side, of the load handling device with the moving sub-chassis removed.

[0176] FIG. 11 illustrates a long side, or yz side, elevation view of an alternative load handling device design in which lifting of the storage container support pads to clear the cradle is accomplished using a third electric or hydraulic ram 305 that is independent of the two redirection mechanism rams.

[0177] 12 illustrates a plan view of the underside xy of the load handling device 301. As can be seen, wheels 303 are located along the long side of the device 301 for movement in the y direction, and wheels 307 are located along the short side of the device which is mounted to a sub-chassis 312 which is held within a holding frame 317. A camera 316 is located at the center of the device 301 for monitoring the positioning and movement of the device 301.

[0178] 13 is a schematic diagram of a controller for a storage system. As mentioned above, the controller or control facility may include multiple software programs running on separate computing devices interlinked by communication facilities. Any suitable architecture is contemplated, as will be appreciated by those skilled in the art. Thus, the controller is shown as multiple separate modules.

[0179] S99 represents an interface to the Store & Retrieve Demand to allow an operator or an interfaced Order Management System to input desired actions of the system to be communicated to other modules of the system.

[0180] A is not shown. S1601 represents a storage system planner / manager for collectively managing the components of the storage system, planning tasks and sending instructions to other modules to work towards a desired outcome of the system.

[0181] S1602 shows a storage container task manager for planning and sending instructions to the load handling devices and workstations.

[0182] S1603 shows an environmental controller module for managing and controlling the environmental parameters in the aisles, on the storage floor, and in the chambers.

[0183] S1606 shows a load handling device charge status manager module for scheduling the load handling device to visit a charge point when necessary, ensuring that the load handling device is not retasked before it has sufficient charge from a charge point, and ensuring that the load handling device is not selected to take on a task for which it does not have sufficient battery or supercapacitor charge.

[0184] S1607 represents a recovery, repair and maintenance manager module for managing the operational capabilities of a fleet of load handling devices and managing the work required to maintain functionality.

[0185] S1608 represents an operator interface to the user that links to the components of the system and provides input to the operator regarding desired actions, data, and feedback.

[0186] S1609 illustrates a load handling device selection & route planning module for planning routes for load handling devices to complete a task.

[0187] S1610 shows a load handling device path clearance module to ensure collision-free and obstacle-free during execution of the planned route.

[0188] S1611 shows a load handling device communication module for receiving commands from and transmitting data to other modules.

[0189] S1612 shows a lift task planner module to provide the capability to move load handling devices between floors.

[0190] S1613 shows a lift communication module for receiving commands from and transmitting data to other modules.

[0191] S1614 shows a workstation controller module for planning and executing tasks for processing storage containers.

[0192] S1615 represents the interfaces to the workstations that allow user input and communication from the system to operators working at the automated and manual workstations.

[0193] Further comments It will be appreciated that the storage system described herein provides a medium to high density storage facility, which therefore provides efficient and cost-effective use of land.

[0194] The vertical scalability of the facility is limited only by the building technology or construction practices, not by the storage facilities and systems themselves.

[0195] Advantageously, it will be appreciated that the storage arrangement is relatively simple in design and requires minimal interaction or connectivity between mechanical components. It may be possible to build the facility within an existing building or multi-function building.

[0196] It will be appreciated that the arrangement of the storage locations advantageously provides rapid or random access to each of the storage containers while maintaining a relatively high storage density.

[0197] It will be appreciated that the number of storage locations on a side aisle may be optimized based on intended use.

[0198] It will be appreciated that the load handling device is simple and therefore may offer improved reliability compared to other systems.

[0199] It will be appreciated that the cost and / or number of MHE requirements or load handling devices may be minimized through optimization of the control facilities of the system.

[0200] It will be appreciated that control of temperature, humidity, and gas composition, e.g., atmospheric nitrogen concentration, for each passageway, or for portions of a passageway, e.g., for each gallery or chamber, can provide efficiency and simplicity, and therefore cost advantages.

[0201] It will be appreciated that very large containers, such as shipping containers, are difficult to store and retrieve in cubic storage and retrieval systems as described in the existing art. It will be appreciated that failure of a Z-lift hoist would require difficult recovery of the containers and / or load handling devices in the system. The substantially single tier system disclosed herein avoids this problem while providing a high density storage and retrieval system.

[0202] Advantageously, the system readily supports full automation at the workstations, as the load handling devices provide transport through the workstations. The workstations may be automated or robotic.

[0203] Fire suppression is easily designed into the system and firewalls are easily designed into the storage areas, thereby improving the safety of the system.

[0204] The storage and retrieval system described above with reference to the drawings allows for control of the growth environment. In addition, the modularity of the system allows for efficient use of space and is easily expandable. The length, width and height of the track grid system can be chosen to fit the available space.

[0205] Although the foregoing specification has attempted to draw attention to those features of the invention which are believed to be particularly important, it is to be understood that the applicant claims protection for any patentable feature or combination of features referred to in this specification and / or shown in the drawings, whether or not specifically emphasized.

[0206] It will be understood that the storage system, method and device can be designed for a particular application using various combinations of the above-mentioned devices and arrangements. It will be understood that all the features described herein above may be used together in a single system. In other embodiments of the invention, some of the features may be omitted. The features may be used in any compatible arrangement. Many variations and modifications not expressly described above are also possible without departing from the scope of the invention as defined in the appended claims.

[0207] In this document, the terms "load handling device" and "bot" may be used interchangeably. The storage container may be a tray and the load handling device may be a tray handling device. The load handling device may be a type of MHE or material handling equipment.

[0208] In this document, the term "movement relative to the gap" is intended to include movement within the gap, for example sliding along the gap, as well as movement into or out of the gap.

[0209] In this document, the phrase "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 either direction (i.e., toward the positive end of the n-axis or toward the negative end of the n-axis).

[0210] In this document, the term "connect" and its derivatives are intended to include the possibilities of direct and indirect connections. For example, "x is connected to y" is intended to include the possibilities of x being directly connected to y with no intervening components, and the possibilities of x being indirectly connected to y with one or more intervening components. If a direct connection is intended, the terms "directly connected," "directly connected," or similar terms would 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 directly supporting and directly contacting y with no intervening components, as well as the possibilities of x indirectly supporting y with one or more intervening components that contact x and / or y.

[0211] 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 includes one and only one y, multiple y, or one or more y and one or more other elements. When an exclusive meaning is intended, the phrase "x consists of y" would be used, meaning that x includes only y and nothing else. The invention as originally claimed in the present application is set forth below. [1] A storage system comprising: at least one storage floor comprising a track network based on a grid system, the track network comprising a first set of track members extending in a first (x) direction and a second set of track members extending in a second (y) direction, the second set of track members extending transversely to the first set of track members in a substantially horizontal plane; The track network includes an access aisle and a storage aisle, the storage aisle including one or more storage locations for receiving storage containers; at least one load handling device operative on said truck network to lift and transport storage containers; A storage system, wherein the storage location comprises a support means for supporting the storage container. [2] The storage system of [1], wherein the track network comprises one or more temporary storage locations provided with support means for supporting storage containers. [3] The track network comprises: The storage system of [1] or [2], further comprising one or more of a charging bay, a passing lane, a siding, a shelter, and / or a passing point. [4] A storage system as described in any one of [1] or 3, wherein the floor is divided into chambers by partition means, the partition means having an opening or hatch through which a load handling device can pass. [5] The storage system of [4], wherein the partition means comprises fire protection means and / or the partition means provides separation between user access and robot access within the system. [6] A structure having two or more vertically disposed floors interconnected by one or more lifts accessible through an access aisle for transporting load handling devices between the floors, the floors being: At least one storage floor and, optionally, A storage system as described in any one of [1] to [5], comprising one or more sky lobby floors for moving between the lifts. [7] A storage system as described in any one of [1] to [6], comprising one or more of a control facility, an environmental control facility means, a safety system, a data collection means, a data communication means, and a communication system. [8] A storage system as described in any of [1] to [7], wherein each floor includes a maintenance area. [9] The storage system of [8], wherein the maintenance area comprises a mezzanine level above at least a portion of the storage location.

[10] A storage system as described in any one of [1] to [9], comprising one or more workstations, optionally each workstation comprising an RFID reader, scanner, or camera for reading identification tags or labels on storage containers.

[11] A control system for controlling and operating the storage system according to any one of [1] to

[10] , An environmental control module; Task planner and A bot path planning module; a bot path clearance module; A communication module; A lift task planner; A bot charge status manager; a data storage and persistence module; a long-term data storage module for providing data to a machine learning algorithm; a restoration, repair, and / or maintenance manager module for modifying plans and schedules to facilitate restoration, repair, and maintenance operations; a machine learning and / or artificial intelligence module designed to fine-tune the system based on previous operating history.

[12] one or more of the following are controllable by the control facility: air temperature independent of one or more storage aisles, chambers, or storage floors; air humidity independent of one or more storage aisles, chambers, or storage floors; and atmospheric gas composition independent of one or more storage aisles or storage floors; and / or The control facility ensures that the correct storage containers are handled at each stage; and / or The control facility of

[11] , wherein the control facility creates an audit record of each action for each storage container.

[13] A cargo handling device and / or a retrieval device for operating under the control of a control facility described in any one of

[11] to

[12] in a storage system described in any one of [1] to

[10] .

Claims

1. A storage system, comprising: at least one storage floor comprising a track network based on a grid system, said track network comprising a first set of track members extending in a first (x) direction and a second set of track members extending in a second (y) direction, said second set of track members extending transversely to said first set of track members in a substantially horizontal plane, wherein: the track network comprising an access aisle and a storage aisle, the storage aisle comprising one or more storage locations for receiving a storage container, wherein each storage location comprises a support means for supporting a storage container; at least one load handling device operating on said track network for lifting and transporting storage containers, wherein said load handling device comprises a support pad on an upper surface that can be vertically raised and lowered; Equipped with The load handling device comprises: moving said storage container from the access aisle to the storage aisle such that said storage container is supported by said support means, and placing said storage container on the elevated support pad in a storage location by lowering said support pad; and configured to move the storage container from the access aisle to the storage aisle until a lowered support pad is positioned under the storage container supported by the support means such that the load handling device can return to the access aisle with the storage container on a raised support pad, and then remove the storage container by raising the support pad above the support means; a lift system comprising: two or more vertically disposed floors interconnected by one or more lifts accessible from an access aisle for transporting load handling devices between the floors; and the two or more vertically disposed floors comprising: A storage system comprising at least one storage floor.

2. The track network comprises: The storage system of claim 1 , further comprising one or more of a charging bay, a pass lane, a siding, a shelter, and / or a pass point.

3. 3. A storage system according to claim 1 or 2, wherein the at least one storage floor is divided into chambers by partition means, the partition means having openings or hatches through which load handling devices can pass.

4. 4. A storage system as claimed in claim 3, wherein the partition means comprises fire protection means and / or the partition means provides separation between user access and robotic access within the storage system.

5. 5. The storage system of claim 1, wherein the two or more vertically disposed floors comprise one or more sky lobby floors for transitioning between lifts.

6. 6. A storage system according to any one of claims 1 to 5, comprising one or more of a control facility, an environmental control facility means, a safety system, a data collection means, a data communication means and a communication system.

7. 7. A storage system according to claim 1, wherein each floor includes a maintenance area.

8. 8. The storage system of claim 7, wherein the maintenance area comprises a mezzanine level above at least a portion of the storage location.

9. 9. A storage system according to any one of claims 1 to 8, comprising one or more workstations.

10. 10. The storage system of claim 9, wherein each workstation includes an RFID reader, scanner, or camera for reading identification tags or labels on storage containers.

11. A control facility for controlling and operating the storage system according to any one of claims 1 to 10, comprising: An environmental control module; Task planner and A bot path planning module; a bot path clearance module; A communication module; A lift task planner; A bot charge status manager; a data storage and persistence module; a long-term data storage module for providing data to a machine learning algorithm; a restoration, repair, and / or maintenance manager module for modifying plans and schedules to facilitate restoration, repair, and maintenance operations; and a machine learning and / or artificial intelligence module designed to fine-tune the storage system based on previous operating history.

12. one or more of an air temperature independent of one or more storage aisles, chambers, or storage floors; an air humidity independent of one or more storage aisles, chambers, or storage floors; an atmospheric gas composition independent of one or more storage aisles or storage floors; and / or The control facility ensures that the correct storage containers are handled at each stage; and / or The control facility of claim 11 , wherein the control facility creates an audit record of each action for each storage container.

13. A load handling device and / or retrieval device for operating under the control of a control facility according to claim 11 or 12 in a storage system according to any one of claims 1 to 10.

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