Picking Station

Abstract

A robotic picking station is provided for use with a cubical automated storage and retrieval system. The picking station is configured to operate on a grid of the storage and retrieval system such that it is received within a single grid cell of the storage and retrieval system. The picking station is mounted to a framework of the storage and retrieval system and comprises one or more robotic arms. The picking station comprises a support means extending below the grid of the storage system and secured beneath the grid. The support means may be connected to a floor of the storage system. The support means may be connected to one or more framework elements.

Description

[Technical field]

[0001] The present invention relates generally to the field of picking stations for use in warehouses and / or fulfillment centers, and more specifically to apparatus and methods relating to robotic picking stations. [Background technology]

[0002] Online retail businesses that sell multiple product lines, such as online grocery stores and supermarkets, need systems capable of storing tens or hundreds of thousands of different product lines. Using a single product stack in such cases may be impractical as a significant amount of floor space would be required to accommodate all of the required stacks. Furthermore, it may be desirable to only store a few items in small quantities, such as perishables or infrequently ordered goods, making a single product stack an inefficient solution.

[0003] International Patent Application No. WO98 / 049075A (Autostore), the contents of which are incorporated herein by reference, describes a system in which a multi-product stack of containers is arranged within a frame structure.

[0004] PCT Publication No. WO2015 / 185628A (Ocado) describes a further known storage and fulfillment system in which a stack of receptacles or containers is arranged within a framework structure. The receptacles or containers are accessed by a load handling device operable on a truck located at the top of the frame structure. The load handling device lifts the receptacle or container from the stack and a number of load handling devices cooperate to access the receptacle or container located at the lowest position of the stack. A system of this type is illustrated diagrammatically in Figures 1 to 4 of the accompanying drawings.

[0005] 1 illustrates an automated storage and retrieval structure 1 comprising upright members 3 and horizontal members 5, 7 supported by upright members 3. The horizontal members 5 extend parallel to each other and to an illustrated x-axis. The horizontal members 7 extend parallel to each other and to an illustrated y-axis and transverse to the horizontal members 5. The upright members 3 extend parallel to each other and to an illustrated z-axis and transverse to the horizontal members 5, 7. The horizontal members 5, 7 form a grid pattern defining a plurality of grid cells. In the illustrated example, the containers 9 are arranged in stacks 11 beneath the grid cells defined by the grid pattern, with one stack 11 of containers 9 per grid cell.

[0006] FIG. 2 shows a large scale plan view of a section of a track structure 13 forming part of and located on top of the horizontal members 5, 7 of the storage structure 1 illustrated in FIG. 1. The track structure 13 may be provided by the horizontal members 5, 7 themselves (e.g. formed in or on the surface of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7. The illustrated track structure 13 comprises x-direction tracks 17 and y-direction tracks 19, i.e. a first set 17 of tracks extending in the x-direction and a second set 19 of tracks extending in the y-direction, transversely to the tracks 17 in the first set 17 of tracks. The tracks 17, 19 define apertures 15 at the centres of the grid cells. The apertures 15 are sized to allow a container 9 located directly below the grid cell to be lifted and lowered through the apertures 15. The x-direction tracks 17 are provided in pairs separated by paths 21 and the y-direction tracks 19 are provided in pairs separated by paths 23. Other arrangements of the track structures may be possible.

[0007] Figure 3 shows multiple load handling devices 31 moving on top of the storage structure 1 illustrated in Figure 1. The load handling devices 31, which may also be referred to as robots 31 or bots 31, are provided with a set of wheels for engaging with a corresponding x-track 17 or y-track 19 to enable the bots 31 to move across the track structure 13 and reach a particular grid cell. The illustrated pair of tracks 17, 19 separated by paths 21, 23 allows the bots 31 to occupy neighboring grid cells (or pass each other) without colliding with each other.

[0008] 4, the bot 31 comprises a body 33 with one or more components mounted therein or thereon that enable the bot 31 to perform its intended functions. These functions may include moving across the storage structure 1 on the track structure 13 and raising or lowering containers 9 (e.g., from or to stacks 11) so that the bot 31 can retrieve or place containers 9 in specific locations defined by the grid pattern.

[0009] The illustrated bot 31 comprises a first set 35 and a second set 37 of wheels mounted on the body 33 of the bot 31 and enabling the bot 31 to move in the x and y directions along the tracks 17 and 19, respectively. In particular, two wheels 35 are provided on the shorter side of the bot 31 as seen in FIG. 4, and two more wheels 35 are provided on the opposite shorter side of the bot 31 (the side and the two more wheels 35 are not visible in FIG. 4). The wheels 35 engage with the track 17 and are rotatably mounted on the body 33 of the bot 31 to enable the bot 31 to move along the track 17. Similarly, two wheels 37 are provided on the longer side of the bot 31 as seen in FIG. 4, and two more wheels 37 are provided on the opposite longer side of the bot 31 (the side and the two more wheels 37 are not visible in FIG. 4). The wheels 37 engage with the track 19 and are rotatably mounted on the body 33 of the bot 31 to enable the bot 31 to move along the track 19.

[0010] The bot 31 also comprises container lifting means 39 configured to raise and lower the container 9. The illustrated container lifting mechanism 39 comprises four tapes or reels 41 connected at their lower ends to a container engaging assembly 43. The container engaging assembly 43 comprises engagement means (which may for example be provided at the corners of the assembly 43 in the vicinity of the tapes 41) configured to engage features of the container 9. For example, the containers 9 may be provided with one or more apertures on their upper side with which the engagement means can engage. Alternatively or additionally, the engagement means may be configured to hook under a rim or lip of the container 9 and / or to pinch or grip the container 9. The tapes 41 may be wound up or unwound to raise or lower the container engaging assembly as required. One or more motors or other means may be provided to effect or control the winding up or down of the tapes 41.

[0011] As can be seen in FIG. 5 , the body 33 of the exemplary bot 31 has an upper portion 45 and a lower portion 47. The upper portion 45 is configured to accommodate one or more operating components (not shown). The lower portion 47 is disposed directly below the upper portion 45. The lower portion 47 comprises a container receiving space or cavity for accommodating at least a portion of a container 9 raised by the container lifting means 39. The container receiving space is sized such that enough container 9 can fit inside the cavity to allow the bot 31 to move across the top track structure 13 of the storage structure 1 without the underside of the container 9 getting caught on the track structure 13 or another portion of the storage structure 1. Once the bot 31 reaches its intended destination, the container lifting means 39 controls the tape 41 to lower the container gripping assembly 43 and the corresponding container 9 from the cavity in the lower portion 47 to the intended position. The intended location may be a stack 11 of containers 9 or an exit point of the storage structure 1 (or an entrance point of the storage structure 1 if the bot 31 moves to collect containers 9 for storage in the storage structure 1). In the illustrated example, the upper portion 45 and the lower portion 47 are separated by a physical partition, although in other embodiments the upper portion 45 and the lower portion 47 may not be physically divided by a particular component or portion of the body 33 of the bot 31.

[0012] In some embodiments, the container receiving space of the bot 31 may not be within the body 33 of the bot 31. For example, in some embodiments, the container receiving space may be adjacent to the body 33 of the bot 31, for example in a cantilever configuration with the weight of the body 33 of the bot 31 counterbalancing the weight of the container to be lifted. In such an embodiment, the frame or arm of the container lifting means 39 may project horizontally from the body 33 of the bot 31, and the tape / reel 41 may be arranged at respective locations on the projecting frame / arm and configured to be raised and lowered from those locations to raise and lower the container into the container receiving space adjacent the body 33. The height at which the frame / arm is mounted on and projects from the body 33 of the bot 31 may be chosen to provide a desired effect. For example, it may be preferable for the frame / arm to project at a high level on the body 33 of the bot 31 to allow a larger container (or multiple containers) to be lifted into the container receiving space directly below the frame / arm. Alternatively, the frame / arms may be positioned to protrude lower below the body 33 (but still high enough to accommodate at least one container between the frame / arms and the track structure 13) to keep the center of mass of the bot 31 lower when the bot 31 is loaded with containers.

[0013] To enable the bot 31 to move on different wheels 35, 37 in first and second directions, the bot 31 includes a wheel positioning mechanism for selectively engaging either the first set of wheels 35 with the first set of tracks 17 or the second set of wheels 37 with the second set of tracks 19. The wheel positioning mechanism is configured to raise and lower the first set of wheels 35 and / or the second set of wheels 37 relative to the body 33, thereby enabling the load handling device 31 to selectively move in either a first direction or a second direction across the tracks 17, 19 of the storage structure 1.

[0014] The wheel positioning mechanism may include one or more linear actuators, rotary components, or other means for raising and lowering at least one set of wheels 35, 37 relative to the body 33 of the bot 31 to move the at least one set of wheels 35, 37 away from and into contact with the tracks 17, 19. In some instances, only one set of wheels is configured to be raised and lowered, such that the act of lowering one set of wheels may effectively lift the other set of wheels away from the corresponding track, while the act of raising one set of wheels may effectively lower the other set of wheels into contact with the corresponding track. In other instances, both sets of wheels may be raised and lowered, advantageously allowing the body 33 of the bot 31 to remain at substantially the same height, thus meaning that the weight of the body 33 and components mounted thereon do not need to be lifted and lowered by the system described with reference to Figures 1-4, which has many advantages and is suitable for a wide range of storage and retrieval operations. In particular, it allows for very high density storage of products which provides a very economical way of storing a wide range of different items in the containers whilst still allowing reasonably economical access to all of the containers 9 when required for picking.

[0015] As shown in Fig. 3, multiple identical load handling devices 31 may be provided so that each load handling device 31 can operate simultaneously to increase the throughput of the system. The system illustrated in Fig. 3 may include specific locations known as ports, where containers can be transferred into or out of the system. Additional conveyor systems (not shown) are associated with each port, so that containers transported to the port by the load handling device 31 can be transported by the conveyor system to another location, e.g., a picking station (not shown). Similarly, containers can be moved by the conveyor system from an external location to a port, e.g., a container filling station (not shown), and transported by the load handling device 30 to the stack 12 to replenish the stock in the system.

[0016] Each load handling device 31 is capable of lifting and moving one container at a time. If a container that is not located at the top of a stack (the "target container") needs to be removed, the container above (the "non-target container") must be moved first to allow access to the target container. This is accomplished in an operation hereafter referred to as "digging". During a digging operation, one of the load handling devices sequentially lifts each non-target container from the stack containing the target container and places it in a vacant position in another stack. The target container can then be accessed by the load handling device and moved to the port for further transport.

[0017] Each of the load handling devices is under the control of a central computer. Each individual container in the system is tracked so that the appropriate container can be removed, transported, and replaced as needed. For example, during an excavation operation, the location of each non-target container is logged so that the non-target containers can be tracked.

[0018] The system described with reference to Figures 1-5 has many advantages and is suitable for a wide range of storage and retrieval operations. In particular, it allows for very high density storage of products, which provides a very economical way of storing a wide range of different items in containers whilst still allowing reasonably economical access to all of the containers when required for picking. Summary of the Invention

[0019] Broadly speaking, the present invention introduces a robotic picking station that can operate on the surface of a grid-based automated storage and retrieval system.

[0020] According to a first aspect of the present invention, there is provided a picking station for use in a grid based storage system comprising a robotic arm and a mounting for mounting the robotic arm to one or more framework members of the storage system such that the robotic arm is configured to be received within a single grid cell of the storage system, wherein in use i) eight grid cells surrounding the picking station are reserved for use by the picking station, and ii) the eight grid cells are divided into a first zone and a second zone, each of the zones comprising one or more grid cells for receiving a shipping container and one or more grid cells for receiving a respective storage container.

[0021] The fixture may further include a support member extending below a surface of the grid. The support member may be connected to one or more framework members of the storage system. The support member may be connected to one or more vertical members of the storage system and / or one or more horizontal members of the storage system. The support member may be connected to a floor of the storage system.

[0022] The fixture may be directly connected to one or more vertical members of the storage system. The fixture may be directly connected to one or more horizontal members of the storage system. The fixture may include a pedestal, which may be connected to one or more framework members of the storage system and configured to be received within a grid cell of the storage system. The pedestal may extend across substantially all of the grid cell in which the picking station is received.

[0023] The picking station may comprise a computing device, which may comprise one or more processing units, one or more volatile data storage units, one or more non-volatile data storage units, and a network interface. Additionally or alternatively, the picking station may be communicatively coupled to such a computing device. The computing device may comprise a controller apparatus configured to, in use, send signals to the picking station to control operation of the robotic arm.

[0024] According to a second aspect of the present invention, there is provided a storage system comprising a first set of tracks extending in a first direction, a second set of tracks extending in a second direction transverse to the first direction so as to form a grid comprising a plurality of grid cells, a framework structure within which the first and second sets of tracks are received such that a stack of containers may be stored beneath each of the plurality of grid cells, and one or more picking stations as described above. The storage system may comprise a plurality of load handling devices for lifting and moving containers stacked in a stack within the storage system, each of the load handling devices may be configured to travel on the tracks above the stack of containers.

[0025] The picking station, in use, may be configured to pick one or more items from a storage container received into the first zone and transfer them into a shipping container in the first zone. Additionally, the multiple load handling devices may remove one or more storage containers from the second zone. The load handling devices may also remove the shipping container from the second zone. The multiple load handling devices may then place one or more storage containers into a grid location in the second zone. The load handling devices may also place the shipping container in the second zone. The picking station may then pick one or more items from a storage container received into the second zone and transfer the picked items into a shipping container in the second zone.

[0026] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numbers indicate the same or corresponding parts, and in which: [Brief description of the drawings]

[0027] [Figure 1] A schematic diagram of an automated storage and retrieval structure is shown. [Diagram 2] FIG. 2 shows a schematic diagram of a plan view of a section of a track structure forming part of the storage structure of FIG. [Diagram 3] 2 shows a schematic diagram of multiple load handling devices moving on top of the storage structure of FIG. 1; [Figure 4] 1 shows a schematic diagram of a load handling device interacting with a container. [Diagram 5] 1 shows a schematic diagram of a load handling device interacting with a container. [Figure 6] FIG. 1 shows a schematic diagram of a robotic picking station according to the present invention. [Figure 7] FIG. 2 shows a schematic diagram of a portion of the storage system shown in FIG. [Figure 8] 1 shows a schematic diagram of a picking method according to the present invention. [Figure 9]FIG. 2 shows a schematic diagram of an overhead view of a storage location with one picking station according to the present invention. [Figure 10] FIG. 1 shows a schematic diagram of an overhead view of a storage system with multiple picking stations according to the present invention. [Figure 11] 2 shows a schematic diagram of an overhead view of a storage system with multiple picking stations according to a further example of the present invention; [Figure 12] 4 shows a schematic diagram of a picking station according to a further example of the invention; [Figure 13] FIG. 8 shows a schematic diagram of a robot arm similar to that described with reference to FIGS. 6 and 7. [Figure 14] FIG. 1 shows a schematic diagram of the connection of a robot arm to a grid structure. [Figure 15] FIG. 8 shows a schematic diagram of a part of a storage system similar to that described with reference to FIG. 7. [Figure 16] FIG. 16 shows a schematic diagram of a portion of a storage system similar to that described with reference to FIG. [Figure 17] 1 shows a schematic diagram of a computing device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] 6 and 7 show schematic diagrams of a robotic picking station 100, comprising a pedestal 110 in which a robotic arm 120 is received. The pedestal 110 is sized and shaped so that it can be received in an aperture 15 of a grid cell formed by intersecting horizontal members 5, 7. The pedestal may be substantially rectangular in shape. The pedestal is connected to the framework of the storage system such that the robotic arm is mounted on the storage system. For example, the pedestal may be connected to one or more of the upright members 3 of the storage system. Alternatively, the pedestal may be connected to one or more of the horizontal members 5, 7 of the storage system. The pedestal may be connected to one or more of the upright members 3 and one or more of the horizontal members 5, 7 of the storage system. The surface of the pedestal may extend substantially across the aperture of the grid cell in which it is received. This will reduce the risk that a dropped product may fall into the storage system and potentially disrupt the operation of the storage system. Alternatively, the surface of the pedestal may extend only partially across the area of ​​the grid cell in which it is received.

[0029] In the alternative, a fixture may be used to connect the robot arm to the framework of the grid structure. One or more fixture members may mount the robot arm, e.g., a base of the robot arm, to one or more members of the storage system. The robot arm may be mounted to one or more upright members of the storage system, one or more horizontal members of the storage system, or one or more upright members and one or more horizontal members of the storage system. The fixture may be configurable such that the picking station may be stored below the level of the grid (see below).

[0030] The robot arm 120 comprises a base 121, a first joint 122, an upper arm 123, a second joint 124, a forearm 125, a third joint 126, and an end effector 127. The base 121 extends substantially vertically from a base and is connected to the upper arm by a first joint, i.e., the shoulder. The upper arm is connected to the forearm by a second joint, i.e., the elbow. The forearm is connected to the end effector by a third joint, i.e., the wrist. The first joint, the second joint, and the third joint can be selectively actuated such that the end effector can be moved along one or more of the x-axis, y-axis, and z-axis (see FIG. 1). This means that the end effector can be moved into a first container and thus actuated to engage a product stored in that container. The product can then be lifted from the first container and the end effector can then be moved to the second container. Once the product is properly positioned within the second container, the end effector may be deactivated so that the product is placed into the second container. The end effector may comprise a suction device, a pair of opposing grippers, multiple fingers, or other known effectors that can be used to grasp and lift the product. It should be understood that the particular configuration of the robotic arm shown in FIG. 6 is purely illustrative and that other configurations of robotic arms can be used. For example, the robotic arm may comprise a greater or lesser number of parts and joints.

[0031] The picking station may further include an optical sensor 128, which may be located on the top surface of the pedestal 110. The optical sensor may be used to identify the product in the picking process. The picking station may include multiple optical sensors. In one example, the picking station may include four optical scanners, one optical scanner located at or near each corner of the pedestal. The or each optical scanner may include a barcode reader. In an alternative configuration, one or more barcode scanners may be mounted on the robotic arm, such that the barcode scanner(s) move with the arm. In a particular implementation, two barcode scanners may be mounted on the arm.

[0032] The picking station may further comprise a camera array 200, which is located above the pedestal and positioned to be able to view the area in which the end effector will operate. Although FIG. 6 shows the camera array 200 having a rectangular configuration, it should be understood that the camera array may take other configurations, e.g., square, oval, cross, etc., or may comprise multiple individual cameras. The camera array may further comprise lighting elements for illuminating the area in which the end effector will operate. The camera array may comprise one or more 3D cameras. The camera array may be suspended from the ceiling of the building housing the storage system.

[0033] The picking station may further comprise one or more cameras mounted on the robotic arm. The camera 129 (see FIG. 7) may be mounted on or near the end effector. The camera may be mounted on or near the wrist. Additionally or alternatively, the camera may be mounted on or near the elbow of the robotic arm. The use of one or more cameras mounted on the robotic arm may be in addition to or as an alternative to the camera array 200. The or each camera may be provided with lighting elements to illuminate the interior of the container when an item is being picked or placed. One or more cameras may be located elsewhere on the picking station. For example, the camera may be used as a barcode scanner. If a barcode scanner(s) is fitted to the arm, the lighting elements of the barcode scanner(s) may be used to illuminate the interior of the container.

[0034] The picking station may further comprise a computing device 130, which may be used to control the movement of the robotic arm and the actuation of the end effector. Images from the camera array may be fed to the computing device for processing to assist in identifying and / or grasping items stored in the container. The computing device may be located beneath the picking station's pedestal. The picking station may alternatively (as shown in FIG. 7) be connected to a remote computing device, for example by a wired Ethernet connection (or other network connection). Such a remote computing device may be used to control multiple picking stations. The remote computing device may be a central computer used to control the load handling devices. In a further alternative, a cloud computing platform may be used to control the picking stations in the storage system. The computing device may be located at or near the camera array 200 such that images captured by the camera array may be processed and then transmitted to the associated picking station. The computing device located at or near the camera array may perform some degree of image pre-processing, and further image processing may be performed at the picking station.

[0035] FIG. 6 shows several containers arranged near a picking station, which provide multiple picking locations. In this example, the picking locations include eight containers directly adjacent to the picking station and two additional containers. These two additional containers are located in the intermediate space of the long edge of the array of eight containers adjacent to the picking station. These ten containers are containers that the end effector can reach so that products can be picked from or into one of the containers. It should be understood that it is not enough for the end effector to be able to reach the top of each of these containers, but that the end effector must be able to reach each of the bottom corners of each of these containers so that products can be picked from the nearly empty containers. It should be understood that the example shown in FIG. 6 is not limiting and that the exact number and location of the picking locations may be modified and are limited by the movement and range of the robotic arm. For example, a robotic arm with a greater reach (e.g., a longer arm, or an arm with a greater number of articulating joints) may increase the number of picking locations associated with the picking station.

[0036] The robotic arm may include more than one different type of end effector. A central computer may send instructions to the robotic arm as to which end effector to use for each different SKU. Alternatively, the robotic arm may determine which end effector to use based on the weight, size, shape, etc. of the product. Previous success and / or failure to grasp and move an item may be used to update the selection of an end effector for a particular SKU. This information may be fed back to the central computer so that success / failure information may be shared between different picking stations. The robotic arm may be capable of changing end effectors. For example, a picking station may include a storage area capable of accepting one or more end effectors. Optionally, the storage area may be located in a pedestal. The robotic arm may be configured such that an end effector in use may be removed from the robotic arm and placed in an end effector storage area. Additional end effectors may then be removably attached to the robotic arm so that they can be used for subsequent picking operations. The end effector may be selected according to the planned picking operation.

[0037] Alternatively or additionally, the modified bot may be used to carry a replacement end effector. If the picking station needs to change end effectors, the modified bot may be routed to the picking station so that the robotic arm can remove the end effector in use and obtain an additional end effector from the modified bot. Such a replacement may allow the robotic arm to better pick different types of products through the use of a different type of end effector, but it may also allow a defective end effector to be replaced without the need to dispatch a technician onto the grid, which would require at least a portion of the grid to be closed off to allow repairs to be made safely.

[0038] The picking stations described above with reference to Figures 6 and 7 include one robotic arm. It is understood that the picking stations may include two or more robotic arms. The picking stations described above with reference to Figures 6 and 7 are shown as occupying one or more grid apertures. It is understood that the picking stations may include multiple adjacent grid apertures. Furthermore, an array of picking stations, each occupying a single grid aperture, may be provided in adjacent grid locations.

[0039] When the robotic arm is not needed for a picking operation, for example when the storage facility is temporarily operating at a lower than normal utilization rate, the robotic arm may be moved to an idle state position such that the arm is fully received within the footprint of the picking station. In such a case, the arm may be substantially vertical or otherwise positioned so as not to extend beyond the footprint of the picking station. Identification of a picking station in the idle state may allow the picking locations associated with that picking station to be temporarily reclassified so that bots can use those grid locations for the movement and / or storage of storage containers. Alternatively, in the idle state, the picking station may be stored beneath the surface of the grid. The grid locations of the picking station may then be temporarily reclassified so that bots can use the grid locations for movement. When a picking station is identified as needing to emerge from the idle state, the picking locations and / or the grid locations of the picking station may be appropriately reclassified prior to the restart of the picking station (and, if appropriate, the emergence of the picking station up the grid).

[0040] The containers in the picking location may be considered storage containers or shipping containers. A storage container is a container that remains in the storage system and holds each of the products that can be transferred from the storage container to the shipping container. A shipping container is a container that is introduced into the storage system when empty and has several different products loaded into it. When a shipping container becomes full, for example, when the products loaded into the shipping container meet a volumetric limit, weight limit, or some other limit, or when all of a specified set of products are loaded into the storage container, the shipping container will be transferred out of the storage system so that it can be loaded into a vehicle for delivery to a customer. A shipping container may comprise one or more bags or cartons into which products can be loaded. A shipping container may be substantially the same size as a storage container. Alternatively, a shipping container may be slightly smaller than a storage container such that the shipping container can be nested within the storage container.

[0041] FIG. 7 shows a schematic diagram of a portion of the storage system shown in FIG. 1. Conventionally, the storage system may include an area where the height of the stacks of the storage system is reduced, i.e., each of the stacks in the truncated area can accommodate fewer containers than the stacks in the remainder of the storage system. A recess 170 is formed below the area of ​​the storage system with the truncated stacks. Conventionally, a picking aisle may be located within this recessed area, and lifting and other transfer mechanisms may be provided to lower the storage containers from the grid surface for picking at the manual picking stations and then return the storage containers to the grid when picking is complete. Although FIG. 7 shows that the reduced height area of ​​the stacks may include several layers of containers, it should be understood that the reduced height area may include a single layer of containers. The manual picking stations and other associated equipment may be located on a mezzanine floor to efficiently use the space beneath the grid.

[0042] A picking station 100 according to an embodiment of the invention may be located on the grid such that it is above the recess 170. The picking station's pedestal 110 may be adapted to engage with the horizontal members 5, 7 that form the grid location 15 in which the picking station is located. Additionally or alternatively, the picking station may be adapted to engage with the vertical members 3 of the stack on which the picking station is received. The picking station may be releasably coupled to the horizontal and / or vertical members (depending on the nature of the picking station's connection to the grid structure) so that it can be stored below the level of the grid. Furthermore, the picking station may be retractable to the extent that it can be retracted into the recess, for example to allow maintenance or repair work. This avoids the need to dispatch a technician onto the grid to perform maintenance or repair activities.

[0043] On-grid picking stations according to the invention can be retrofitted to existing storage systems so that they can operate in a hybrid fashion, with picking being performed on the grid, in recesses in the storage system and / or at picking stations located elsewhere. If sufficient picking stations according to the invention are provided on the grid, it may be possible to remove some or all of the picking stations located directly below the grid structure. As these picking stations and the associated lifting and transport mechanisms require much more space than is required to maintain and service the on-grid picking stations, it would be possible to reduce the size of the recesses. This can be achieved by extending some of the truncated height stacks, for example to floor level, so that the space available for the storage containers can be increased.

[0044] A robotic picking station may automatically pick items from a storage container and then transfer them to a shipping container, where, for example, products may be packed into bags held within the shipping container, but there may be conditions in which the robotic arm is unable to effectively grasp a product item, for example, due to the orientation of the item in the storage container relative to other product items. In such cases, repeated failure to grasp the item may cause an alert to be raised so that an operator may remotely operate the robotic arm and override the automated operation of the robotic arm. The controller device 1750 may be communicatively connected to the computing device 130 such that control commands may be sent to the robotic arm and cause it to respond accordingly. The controller device 1750 may comprise a keyboard 1715 and a mouse 1712 of the computing device 130. Alternatively or in addition, the controller device 1750 may comprise a modified game controller (or similar handheld device) and / or a virtual reality or augmented reality headset or other device or interface.

[0045] The teleoperation of the robotic arm may comprise an operator having full control of the robotic arm, so that components of the robotic arm are rotated or moved to bring the end effector into the proper position relative to the product to be picked. The end effector may then be actuated to grip the product, which may then be transferred to a shipping container (or a bag or carton within the shipping container). In an alternative, the operator may use a controller device to define the area of ​​the item to be picked, for example, a flat surface of a box when the end effector comprises a suction end effector. The defined area may then be used by the robotic picking arm as input to an automated picking attempt. If the automated picking attempt is still unsuccessful, the operator may fully operate the arm to pick the item, as described above. It should be appreciated that some form of machine learning techniques may be used to enable automated operation of the robotic picking arm. In such a case, data generated during the teleoperation of the robotic arm by the teleoperator may be used to improve the algorithms used in the automated operation of the robotic picking arm.

[0046] The process by which a customer order may be picked will now be described with reference to FIG. 8, which shows a schematic diagram of a picking method according to the present invention. In step 800, a customer order to be picked is accessed and processed. A central computer includes an ordering system that manages the delivery of the customer order and arranges for the order to be picked so that the order can be delivered to the customer in a predefined time slot and so that the order can be dispatched for delivery. In step S810, each of the products comprising the customer order processed in S800 is identified and a respective storage container location for each product is determined. In step 820, each of the storage container locations is assigned to one or more bots. It should be understood that the number of bots required to efficiently pick a customer order varies depending on the number of storage containers that must be retrieved to fulfill the customer order, the location of the storage containers relative to the picking station, etc. A bot may perform multiple storage container retrieval movements during the fulfillment of a customer order.

[0047] In step 830, the or each bot is assigned to a picking station. It should be understood that a storage system may include multiple zones, e.g., refrigerated zones, frozen zones, ambient temperature zones, etc., and an order will likely include products from more than one of these zones. Furthermore, each of the zones will include one or more picking stations, e.g., because refrigerated products need to be picked at a picking station in a refrigerated zone of the storage system. The assignment of bots to picking stations may be made according to the characteristics of the product to be picked and / or the picking station. For example, if a product is best suited to be picked by a suction end effector, the product will be assigned to a picking station that is operating with a suction end effector (or that can be reconfigured to operate with a suction end effector by the time the product is delivered to the picking station).

[0048] In step S840, the or each bot is actuated to move to the location of the assigned storage container so that the storage container can be retrieved. If the storage container is not at the top of the container stack, a dig process (see above) will be implemented to retrieve the storage container. The bot may autonomously determine its own route across the grid to the assigned storage container location, or a route may be determined and then transmitted to the bot. The route may be determined by a central computer. The manner in which the bot may determine its route across the grid is disclosed in the applicant's co-pending application WO2017 / 186825. The manner in which communication to and from the bot may be performed is disclosed in the applicant's co-pending application WO2015 / 185726.

[0049] In step S850, the retrieved storage container is moved by the bot to one of a plurality of picking locations of the picking station to which the bot is assigned. An identification of the picking location to be used may be determined and communicated to the bot. The bot then places the retrieved storage container in the picking location to be used and moves to a further grid location. In step S860, a picking process is performed such that one or more of the products held in the storage container are each moved to a shipping container. The storage container may be received in a picking location adjacent to the picking location of the shipping container. One or more of the products may each be picked from the storage container into two or more shipping containers. The two or more shipping containers may be associated with different customer orders. Once picking from the storage container is completed, in step S870, the bot moves to the picking location of the storage container and retrieves the storage container from the picking location in the grid. In step S880, the bot moves the storage container to a further grid location and places the storage container in the grid. Alternatively, the process may return to step S850 and the bot moves to a further picking location so that the removed storage container can be placed in the further picking location.

[0050] It should be understood that the storage container may be returned to the grid location from which it was retrieved in step S840, but may alternatively be placed in another grid location. If the products held in the storage container are needed for a relatively short period of time, the storage container may be placed in a grid location relatively close to the picking station to reduce the time required to retrieve the storage container for a subsequent picking operation. The bot that placed the storage container in step S850 may wait for the end of the picking process to retrieve the storage container in step S870. Alternatively, the bot may be allocated to a different task, e.g., retrieving additional storage containers whose picking processes have been completed, such that there is a more efficient utilization of the bot. In such a case, additional bots will be allocated to retrieve storage containers once the picking process is completed.

[0051] It should be understood that the order of some of the steps of the method described above with reference to Figure 8 may be changed without affecting the performance of the picking station. For example, the allocation of the bot, the storage container to be retrieved, and the picking station may occur in one step. In a further example, once the bot retrieves an identified storage container (S840), the bot may be assigned to a picking station (S830). Additionally, one or more bots may be assigned to a particular picking station and then assigned a storage container to retrieve and deliver to the assigned picking station so that the product may be picked from the storage container.

[0052] FIG. 9 shows a schematic diagram of an overhead view of the storage system of FIG. 1 with one picking station according to the present invention. FIG. 9 shows the picking station 100 surrounded by multiple picking locations 150. In an illustrative manner, a first bot may place a first shipping container in picking location 150B. This allows additional bots to place storage containers in picking locations 150A and 150C. For example, while the picking station is transferring products from the first storage container in picking location 150A into a shipping container, one bot may be removing a second storage container from picking location 150C so that an additional bot can place a third storage container in picking location 150C. Once picking from the first storage container is completed, the picking station may pick one or more items from the third storage container received in picking location 150C. While the picking station is picking products from the third storage container, the bot may also remove the first storage container from picking location 150A so that a further bot may place a fourth storage container in picking location 150A.

[0053] In a further illustrative method, shipping containers may be placed in shipping locations 150B and 150D. Picking locations 150A and 150G may be used for storage containers to be used when picking into a shipping container held in picking location 150B. Picking locations 150E and 150F may be used for storage containers to be used when picking into a shipping container held in picking location 150D. Picking location 150C may be used for storage containers that may be used when picking into either the shipping container held in picking location 150B or the shipping container held in picking location 150D. It can be seen that it is advantageous to control the location of the shipping containers and storage containers so that the shipping containers are adjacent to the storage containers. This reduces the distance that products need to be moved during the picking process and reduces the time required to pick each product.

[0054] FIG. 9 also shows two arrows, which provide a schematic diagram of an example of a bot's movement when placing or removing a container. In this example, the bot approaches picking location 150C in a first direction along the grid (as shown by arrow A). Once the container is placed (or removed), the bot leaves picking location 150C in a second direction along the grid (as shown by arrow B), i.e., perpendicular to the first direction. Such an arrangement reduces the risk that a bot leaving the picking station will obstruct further bots approaching the picking station.

[0055] It should be understood that grid cells that are not occupied by a robotic picking station or designated as a picking location 150 may be considered storage locations in that they are reserved to hold storage containers that contain products to be picked, or shipping containers that have been picked and are temporarily stored before an order comprising one or more shipping containers is routed for loading into a delivery vehicle.

[0056] FIG. 10 shows a schematic diagram of an overhead view of the storage system of FIG. 1 with multiple picking stations according to the present invention. In this example, the storage system comprises a first and a second picking station 100A, 100B and multiple picking locations. The first and second picking stations are arranged such that there are three shared picking locations, i.e. six picking locations that are only addressable by the first picking station and six picking locations that are only addressable by the second picking station. This allows storage containers for products with high demand to be placed in the picking locations so that both the first and second picking stations can access the products. As discussed above with reference to FIG. 10, it is advantageous for the shipping containers to be placed in the picking locations so that they are adjacent to one or more storage containers.

[0057] It should be understood that the arrangement of picking stations shown in Figure 10 can be adapted to include more than two picking stations. The picking stations may be arranged such that they have a common picking location, as shown in Figure 10, or there may be a greater degree of separation between the picking stations. A storage system may include one or more single picking stations (as shown in Figure 9) and / or one or more multiple picking stations (as shown in Figure 10).

[0058] 11 shows a schematic diagram of an overhead view of a storage system as shown in FIG. 1 with multiple picking stations according to a further example of the present invention. In this further example, each of the picking stations 100 is surrounded by eight picking locations 150 such that the picking station and associated picking locations are comprised of a 3×3 block grid location. Otherwise, the operation of the picking stations and their interaction with the multiple bots is as described above.

[0059] Compared to the picking stations discussed above with reference to FIG. 9, the picking capacity of each individual picking station is slightly reduced since only eight picking locations are used instead of ten, however, it has been found that the overall system performance is improved since more of the eight cell picking stations can be fitted onto the surface of the grid. In particular, it has been found that by using eight cell picking stations instead of ten cell picking stations, it is possible to increase the density of the picking stations by 33%. A further advantage of the eight cell picking stations is that it is possible to achieve a higher proportion of short moves, i.e., picking moves that are made when the storage container is located adjacent to the shipping container. It has been found that separating each picking station by only three grid cells in both the X and Y directions from the next picking station provides the optimal balance. If the picking stations are close together, it becomes less efficient to transport containers to and from the picking stations as the grid becomes more crowded, resulting in a decrease in system performance. If the picking stations are further apart, a reduction in the number of picking stations has a greater impact on system performance.

[0060] FIG. 12 shows a schematic diagram of a picking station according to a further example of the invention, in which a robotic picking station 100 is surrounded by eight picking locations 150a-150h. In this example, picking locations 150d and 150e are reserved for use with shipping containers, while picking locations 150a-150c and 150f-150h are reserved for use with storage containers. The picking locations may be allocated in one of two zones. For example, picking locations 150a, 150b, 150d, and 150f are associated with a first zone of the picking station, and picking locations 150c, 150e, 150g, and 150h are associated with a second zone of the picking station. The robotic picking station may be performing a picking operation in one of the zones while containers are being exchanged in the other zone of the picking station.

[0061] For example, consider that a shipping container is present in picking location 150d and that storage containers present in picking locations 150a, 150b, and 150f each contain a product (or products) to be picked as part of a customer order. Appropriate commands can be sent to a robotic picking arm to pick the appropriate number of product items from each of the storage containers present in picking locations 150a, 150b, and 150f, and the product items can be transferred to the shipping container present in picking location 150d.

[0062] Substantially simultaneously as these picking operations are being performed, one or more bots are instructed to remove storage containers present in picking locations 150c, 150g, and 150h so that additional storage containers can be placed in picking locations 150c, 150g, and 150h, the additional storage containers containing the product (or products) to be picked as part of the customer order. To maintain efficiency of the picking process, three bots may be used to remove the storage containers present in picking locations 150c, 150g, and 150h, and three more bots may be used to deliver the additional storage containers to picking locations 150c, 150g, and 150h. If the shipping container present in picking location 150e is full, it may also be removed by a bot and replaced with an additional shipping container, for example, using an additional bot.

[0063] From this, a picking process is performed in a first zone of the picking station, while a replenishment process is performed in a second zone of the picking station. Once both of these processes are completed, the robot arm can be rotated to perform a picking process in the second zone of the picking station, i.e., pick one or more items from the storage containers present in picking locations 150c, 150g, and 150h into a shipping container present in picking location 150e. At the same time, one or more bots can be operated to perform a replenishment process in the first zone of the picking station, i.e., remove the storage containers present in picking locations 150a, 150b, and 150d and then replace them with further storage containers (and, if necessary, replace the shipping container present in picking location 150d). It can be seen that these processes can be completed iteratively, such that one zone of the picking station is used for picking while the other zone of the picking station is replenished.

[0064] The picking process described above with reference to Figures 8-12 may be adapted for use in a stock consolidation process. If a single product is present in small numbers in two or more storage containers, the multiple storage containers may be transported by a bot to a robotic picking station 100. The picking station may then transfer the product into a single storage container such that one or more storage containers are emptied. The empty container(s) may then be routed to a decanting facility so that new product can be placed into them.

[0065] FIG. 13 shows a schematic diagram of a robot arm 120 similar to that described above with reference to FIGS. 6 and 7, comprising a base 121, a first joint 122, an upper arm 123, a second joint 124, a forearm 125, a third joint 126, and an end effector (not shown). The robot arm is fixed to the horizontal members of the grids 5, 7 with base members 116, 118 fixed on either side of the grid cell in which the robot arm is received. These members are arranged to allow the bot to move along the tracks of the grid cells adjacent to the robot picking station. FIG. 14 shows a schematic diagram of the connection of the robot arm 120 to the horizontal member 7 of the grid structure. It can be seen that the base member 118 can be clamped to the horizontal member 7 with a resilient member 119 received in the track 19 closest to the grid cell to reduce vibrations transmitted from the grid structure into the robot camera. The resilient member can also allow the picking arm to be centered within the grid cell so that the picking arm is accurately positioned. Other tracks 19 in the horizontal member 7 are found to be free to allow the bot to access grid cells adjacent to the picking station.

[0066] Figure 15 shows a schematic diagram of a portion of a storage system similar to that described above with reference to Figure 7. Figure 15 shows a floor 60 beneath the storage system. Figure 15 also shows that the picking station further comprises a support member 112 beneath the surface of the grid, extending down to the floor 60, where a support mounting 114 connects the support member 112 to the floor. The floor 60 may be a mezzanine level within a warehouse, or may be a ground floor on which the storage and retrieval system is mounted. Mounting the support member to the floor may reduce vibrations transmitted from the grid to the robotic picking arm.

[0067] FIG. 16 shows a schematic diagram of a portion of a storage system similar to that described above with reference to FIG. 15. FIG. 16 shows that a support member 112 extends beneath the surface of the grid, and one or more support mountings 114 may be provided for mounting the support member to one or more of the upright members 3 and / or one or more of the horizontal members 5, 7 of the grid structure. Mounting the camera array support in this manner may reduce vibration of the camera array. For example, a support mounting 114A may be connected to one or more of the upright members of a grid cell. In a further example, a support mounting 114B may be connected to the top of one or more of the horizontal members 5, 7 of the grid cell. The support mounting 114B may be further connected to one or more of the upright members of the grid cell. In an alternative form, a support mounting 114C may be connected to the underside of one or more of the horizontal members 5, 7 of the grid cell. The support mounting 114C may be further connected to one or more of the upright members of the grid cell. In yet a further example, the support mounting 114D may be connected to both the top and the underside of one or more of the horizontal members 5, 7 of the grid cell. The support mounting 1114D may further be connected to one or more of the upright members of the vertically adjacent grid cells. It should be appreciated that the support mounting preferably does not extend into the space of the horizontally adjacent grid cells as this may interfere with the storage and retrieval of containers. It should be appreciated that the arrangements described above with respect to Figures 15 and 16 can be combined such that the support member 112 may be connected to the floor 60 and the top of the support member may be connected to one or more of the upright members 3 and / or one or more of the horizontal members 5, 7 of the grid structure using one or more support mountings 114. The use of the support mounting 114 to secure the camera array support may reduce vibration of the camera array.

[0068] A suitably configured computing device 130 and associated communication networks, devices, software, and firmware may provide a platform for enabling one or more embodiments as described above. By way of example, FIG. 17 shows a schematic diagram of a computing device 130 that may include a central processing unit ("CPU") 1702 connected to a storage unit 1714 and a random access memory 1706. The CPU 1702 may process an operating system 1701, application programs 1703, and data 1723. The operating system 1701, application programs 1703, and data 1723 may be stored in the storage unit 1714 and loaded into the memory 1706 as needed. The computing device 130 may further include a graphics processing unit (GPU) 1722 operatively connected to the CPU 1702 and the memory 1706 to offload intensive image processing operations from the CPU 1702 and perform these operations in parallel with the CPU 1702. An operator 1707 may interact with the computing device 130 using various input / output devices, such as a video display 1708 connected by a video interface 1705, and a keyboard 1715, a mouse 1712, and a disk drive or solid state drive 1714 connected by an I / O interface 1704. In a known manner, the mouse 1712 may be configured to control cursor movement in the video display 1708 and to operate various graphical user interface (GUI) controls that appear in the video display 1708 with mouse buttons. The disk drive or solid state drive 1714 may be configured to accept a computer readable medium 1716. The computing device 130 may form part of a network via a network interface 1711, enabling the computing device 130 to communicate with other appropriately configured data processing systems (not shown). One or more different types of sensors 1735 may be used to receive input from various sources.

[0069] The system and method may be implemented on virtually any type of computing device, including a desktop computer, a laptop computer, a tablet computer, or a wireless handheld. The system and method may also be implemented as a computer readable / usable medium that includes computer program code for enabling one or more computing devices to perform each of the various process steps in the method according to the invention. When multiple computing devices perform the entire operation, the computing devices are networked to distribute the various steps of the operation. It should be understood that the term computer readable medium or computer usable medium comprises one or more of any type of physical embodiment of the program code. In particular, the computer readable / usable medium may comprise program code embodied on one or more portable storage products (e.g., optical disks, magnetic disks, tapes, etc.), on one or more data storage portions of a computing device, such as memory associated with a computer and / or storage system.

[0070] In further aspects, the present disclosure provides systems, devices, methods, and computer programming products including non-transitory machine-readable instruction sets for use in implementing such methods and enabling the functionality previously described.

[0071] In this document, the phrase "movement in the n-direction" (and related phrases), where n is one of x, y, and z, 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). In this document, the word "connect" and its derivatives are intended to include the possibility of direct connection and indirect connection. For example, "x is connected to y" is intended to include the possibility of x being directly connected to y with no intervening components and the possibility of x being indirectly connected to y with one or more intervening components. If a direct connection is intended, the words "directly connected", "directly connected", or similar words would be used. Similarly, the word "support" and its derivatives are intended to include the possibility of direct contact and indirect contact. For example, "x supports y" is intended to include the possibility that x directly supports and directly contacts y without any intervening components, and the possibility that x indirectly supports y with one or more intervening components that contact x and / or y. The word "mount" and its derivatives are intended to include the possibility of direct and indirect mounting. For example, "x is mounted on y" is intended to include the possibility that x is directly mounted on y without any intervening components, and the possibility that x is indirectly mounted on y with one or more intervening components. 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, as well as one or more other elements. When the exclusive meaning is intended, the phrase "x consists of y" will be used, which would mean that x includes only y and nothing else. In this document, a "controller" is intended to include any hardware suitable for controlling (eg, providing instructions to) one or more other components.For example, a processor equipped with one or more memories and appropriate software for processing data relating to one or more components and sending appropriate instructions to the component(s) to enable the component(s) to perform its / their intended function(s).

[0072] In one aspect, the invention relates to a robotic picking station provided for use with a cubical automated storage and retrieval system. The picking station is configured to operate on a grid of the storage and retrieval system such that it is received within a single grid cell of the storage and retrieval system. The picking station is mounted to a framework of the storage and retrieval system and comprises one or more robotic arms. The picking station comprises a support means extending below the grid of the storage system and secured beneath the grid. The support means may be connected to a floor of the storage system. The support means may be connected to one or more framework elements. The following is a summary of the claims as originally filed: [1] A picking station for use in a grid-based storage system, the picking station comprising: A robot arm; a fixture for mounting the robotic arm to one or more framework members of the storage system such that the robotic arm is configured to be received within a single grid cell of the storage system; and During use, i) eight of the grid cells surrounding the picking station are reserved for use by the picking station; ii) a picking station, wherein the eight grid cells are divided into a first zone and a second zone, each zone having one or more grid cells for receiving a shipping container and one or more grid cells for receiving a respective storage container. [2] The picking station of [1], wherein the fixture includes a support member extending below the surface of the grid. [3] The picking station described in [2], wherein the support member is connected to one or more framework members of the storage system. [4] A picking station as described in [2] or [3], wherein the support member is connected to one or more vertical members of the storage system. [5] A picking station described in any one of [2] to [4], wherein the support member is connected to one or more horizontal members of the storage system. [6] A picking station described in any one of [2] to [5], wherein the support member is connected to a floor of the storage system. [7] A picking station described in any one of [1] to [6], wherein the eight grid cells surrounding the picking station are divided into a first zone and a second zone, each zone having one grid cell for receiving a shipping container and three grid cells for receiving respective storage containers. [8] A picking station described in any one of [1] to [7], wherein the fixture is directly connected to one or more vertical members of the storage system. [9] A picking station described in any one of [1] to [8], wherein the fixture is directly connected to one or more horizontal members of the storage system.

[10] A picking station described in any one of [1] to [9], wherein the fixture comprises a base, the base being connected to one or more framework members of the storage system and configured to be received within a grid cell of the storage system.

[11] The picking station described in

[10] , wherein the base extends across substantially all of the grid cells in which the picking station is received.

[12] The picking station according to any one of [1] to

[11] , further comprising one or more cameras.

[13] The picking station described in

[12] , wherein one or more cameras are mounted above the picking station.

[14] A picking station as described in

[12] or

[13] , wherein one or more cameras are mounted on the robot arm.

[15] A picking station as described in any one of [1] to

[14] , wherein the fixture is equipped with one or more optical sensors.

[16] A picking station described in any one of [1] to

[15] , wherein one or more barcode scanners are mounted on the robot arm.

[17] The picking station described in any one of [1] to

[16] , wherein the picking station comprises a computing device, the computing device comprising one or more processing units, one or more volatile data storage units, one or more non-volatile data storage units, and a network interface.

[18] A picking station described in any one of [1] to

[16] , wherein the picking station is communicatively coupled to a computing device, the computing device comprising one or more processing units, one or more volatile data storage units, one or more non-volatile data storage units, and a network interface.

[19] The picking station of

[17] or

[18] , wherein the computing device comprises a controller device configured, during use, to send signals to the picking station to control operation of the robotic arm.

[20] The picking station described in any one of [1] to

[19] , wherein the robot arm is equipped with one or more end effectors.

[21] The picking station of

[20] , wherein the robot arm is configured to exchange a first end effector with a second effector.

[22] A picking station described in any one of [1] to

[21] , wherein the robotic arm, during use, is configured to select an item from a container received in a first grid cell and transfer the item to a container received in a second grid cell.

[23] The picking station described in any one of [1] to

[22] , wherein the picking station is equipped with a plurality of robotic arms.

[24] A picking station described in any one of [1] to

[23] , wherein the picking station is configured to be stored below a surface of the storage system during use.

[25] A storage system comprising: a first set of tracks extending in a first direction; a second set of tracks extending in a second direction transverse to the first direction to form a grid having a plurality of grid cells; a framework structure within which the first set of trucks and the second set of trucks are received such that a stack of containers may be stored beneath each of a plurality of the grid cells; and [1] to

[24] , and one or more picking stations according to any one of the above. A storage system comprising:

[26] The storage system described in

[25] , wherein the storage system comprises a plurality of load handling devices for lifting and moving containers stacked in stacks within the storage system, each of the load handling devices configured to move on the track above the stack of containers.

[27] The storage system of

[26] , wherein the picking station, when in use, is configured to pick one or more items from the storage container received into the first zone and transfer them into the shipping container in the first zone.

[28] The storage system of

[27] , wherein a plurality of load handling devices remove one or more storage containers from the second zone.

[29] The storage system of

[28] , wherein a cargo handling device removes the shipping container from the second zone.

[30] A storage system as described in

[28] or

[29] , wherein a plurality of cargo handling devices place one or more storage containers in grid locations in the second zone.

[31] The storage system according to

[30] dependent on

[29] , wherein a cargo handling device places a shipping container in the second zone.

[32] The storage system of

[31] , wherein the picking station is configured to then pick one or more items from the storage container received in the second zone and transfer the picked items into the shipping container in the second zone.

Claims

1. 1. A picking station for use in a grid based storage system, the picking station comprising: A robot arm; a mounting fixture for mounting the robotic arm to one or more framework members of the storage system such that the robotic arm is configured to be received within a single grid cell of the storage system; and During use, i) eight of the grid cells surrounding the picking station are reserved for use by the picking station; ii) a picking station, wherein the eight grid cells are divided into a first zone and a second zone, each zone comprising one or more grid cells for receiving a shipping container and one or more grid cells for receiving a respective storage container.

2. The picking station of claim 1 , wherein the fixture comprises a support member extending below a surface of a grid.

3. The picking station of claim 2 , wherein the support member is connected to one or more framework members of the storage system.

4. The picking station of claim 2 or 3, wherein the support member is connected to one or more vertical members of the storage system.

5. The picking station of claim 2 or 3, wherein the support member is connected to one or more horizontal members of the storage system.

6. The picking station of claim 2 or 3, wherein the support member is connected to a floor of the storage system.

7. 4. The picking station of claim 1, wherein the eight grid cells surrounding the picking station are divided into a first zone and a second zone, such that each zone comprises one grid cell for receiving a shipping container and three grid cells for receiving respective storage containers.

8. A picking station according to any one of claims 1 to 3, wherein the fixture is directly connected to one or more vertical members of the storage system.

9. A picking station according to any one of claims 1 to 3, wherein the fixture is directly connected to one or more horizontal members of the storage system.

10. 4. The picking station of claim 1, wherein the fixture comprises a pedestal, the pedestal being connected to one or more framework members of the storage system and configured to be received within a grid cell of the storage system.

11. The picking station of claim 10 , wherein the pedestal extends across substantially all of the grid cell in which the picking station is received.

12. The picking station of any one of claims 1 to 3, further comprising one or more cameras.

13. The picking station of claim 12 , wherein one or more cameras are mounted above the picking station.

14. The picking station of claim 12 , wherein one or more cameras are mounted on the robotic arm.

15. A picking station according to any preceding claim, wherein the fixture comprises one or more optical sensors.

16. A picking station according to any preceding claim, wherein one or more barcode scanners are mounted on the robotic arm.

17. The picking station of any one of claims 1 to 3, wherein the picking station comprises a computing device, the computing device comprising one or more processing units, one or more volatile data storage units, one or more non-volatile data storage units, and a network interface.

18. The picking station of any one of claims 1 to 3, wherein the picking station is communicatively coupled to a computing device, the computing device comprising one or more processing units, one or more volatile data storage units, one or more non-volatile data storage units, and a network interface.

19. The picking station of claim 17 , wherein the computing device comprises a controller apparatus configured, in use, to send signals to the picking station to control operation of the robotic arm.

20. The picking station of any one of claims 1 to 3, wherein the robotic arm comprises one or more end effectors.

21. 21. The picking station of claim 20, wherein the robotic arm is configured to exchange a first end effector with a second effector.

22. 4. The picking station of claim 1, wherein the robotic arm is configured, in use, to select an item from a container received in a first grid cell and transfer the item to a container received in a second grid cell.

23. The picking station of any one of claims 1 to 3, wherein the picking station comprises a plurality of robotic arms.

24. A picking station according to any preceding claim, wherein the picking station is configured, in use, to be stored below a surface of the storage system.

25. 1. A storage system comprising: a first set of tracks extending in a first direction; a second set of tracks extending in a second direction transverse to the first direction to form a grid comprising a plurality of grid cells; a framework structure within which the first set of trucks and the second set of trucks are received such that a stack of containers may be stored beneath each of a plurality of the grid cells; and One or more picking stations according to any one of claims 1 to 3; A storage system comprising:

26. 26. The storage system of claim 25, wherein the storage system comprises a plurality of load handling devices for lifting and moving containers stacked in stacks within the storage system, each of the load handling devices configured to travel on the track above the stack of containers.

27. 27. The storage system of claim 26, wherein the picking station is configured, in use, to pick one or more items from the storage container received into the first zone and transfer them into the shipping container in the first zone.

28. 30. The storage system of claim 27, wherein a plurality of load handling devices remove one or more storage containers from the second zone.

29. 30. The storage system of claim 28, wherein a load handling device removes the shipping container from the second zone.

30. 30. The storage system of claim 28, wherein a plurality of load handling devices place one or more storage containers in grid locations in the second zone.

31. 31. The storage system of claim 30 when dependent on claim 29, wherein a cargo handling device places a shipping container in the second zone.

32. 32. The storage system of claim 31 , wherein the picking station is configured to then pick one or more items from the storage container received into the second zone and transfer the picked items into the shipping container in the second zone.

Images