Storage and Retrieval Systems

Abstract

To increase speed of transferring a commodity to a different storage level and from the different storage level in a storage and taking-out system.SOLUTION: An automatic storage and taking-out system comprises: at least one autonomous conveyance vehicle 110; a transfer deck which has a plurality of moving lanes and defines a nondeterministic conveyance surface for the at least one autonomous conveyance vehicle 110; at least one reciprocating lift 150B1, 150B2; and at least one picking face delivery station TS which is connected to the transfer deck so that a picking face is transferred between the at least one reciprocating lift 150B1, 150B2 and the at least one autonomous conveyance vehicle 110, for interaction between the at least one autonomous conveyance vehicle 110 on the transfer deck and at least one reciprocating lift 150B1, 150B2.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application is a nonprovisional application claiming the benefit of U.S. Provisional Patent Application No. 62 / 104,513, filed January 16, 2015, U.S. Provisional Patent Application No. 62 / 104,552, filed January 16, 2015, and U.S. Provisional Patent Application No. 62 / 104,531, filed January 16, 2015, the disclosures of which are incorporated herein by reference in their entireties.

[0002] [Technical field] FIELD OF THE DISCLOSURE The illustrative embodiments relate generally to material processing systems, and more particularly, to the transport and storage of items within material processing systems. [Background technology]

[0003] A multi-level storage and retrieval system may be used in a warehouse for the storage and retrieval of goods. Generally, the transport of goods into and out of the storage structure is performed by a vehicle including a lift for transfer to a vehicle on a storage level, a vehicle moving up a ramp to the storage level, or a lift moving along a guideway. The goods stored in the storage and retrieval system are generally stored in a storage space on each storage level, and the transport vehicle located on that storage level has access to one level of the storage space. Generally, the lifts that transfer items to and from the storage spaces and carry the vehicles between the different storage levels are built into the vehicles (such as by a gantry crane) or have a paternoster configuration in which the loading shelves of the lifts are continuously circulated around a frame at a predetermined speed.

[0004] Typically, the sequencing of goods removed from storage is performed by the vehicle that removes the goods, or by a dedicated sorter that sorts the goods during the outgoing flow after they have been transported by a gantry crane or paternoster lift. Sorting outgoing goods in this manner can result in multiple lift strokes to remove goods required for load removal or additional sorting steps, and thus a reduced throughput of the storage and retrieval system. Summary of the Invention

[0005] It would be advantageous to increase the speed of transfer of goods to and from different storage levels within a storage and retrieval system that is independent of the transport vehicle that delivers the goods to the storage space. It would also be advantageous to increase the speed of transfer of goods to and from different storage levels within a storage and retrieval system where goods in a load discharge are sorted at a lift interface and retrieved by a common lift stroke, and the order of the sorted goods at the lift interface is compatible with the common load, lift interface, and / or lift. [Brief description of the drawings]

[0006] The foregoing aspects and other features of the disclosed embodiments are explained in the following description and in conjunction with the accompanying drawings.

[0007] [Figure 1] 1 is a schematic diagram of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1A] 1 is a schematic diagram of a portion of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1B] 1 is a schematic diagram of a portion of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1C] FIG. 1 is a schematic illustration of a mixed pallet load formed by an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1D] 1 is a schematic diagram of a portion of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1E] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 2A] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 2B] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 3A] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 3B] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 4A] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 4B] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Diagram 5] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 5A] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 5B] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 5C] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 5D] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 6] 1 is a schematic diagram of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 6A] 1 is a schematic diagram of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 7]1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 8] 1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 9] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 9A] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 9B] 1 is a flowchart in accordance with an aspect of the disclosed embodiment; [Figure 10] 1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10A] 1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10B] 1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10C] 1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10D] 1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10E] 1 is a schematic diagram of a portion of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10F] 1 is a flowchart in accordance with an aspect of the disclosed embodiment; [Figure 10G] 1 is a flowchart in accordance with an aspect of the disclosed embodiment; [Figure 10H] 1 is a flowchart in accordance with an aspect of the disclosed embodiment; [Figure 11] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 12] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 13] 1 is a schematic diagram of a portion of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 14]1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 14A] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 15] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 16] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 17] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 18] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 19] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 20] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; [Figure 21] 1 is a schematic diagram of an operator station of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 22] 1 is an exemplary flow chart in accordance with aspects of the disclosed embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] 1 is a schematic diagram of an automated storage and retrieval system 100 in accordance with aspects of the disclosed embodiment. Although aspects of the disclosed embodiment will be described with reference to the drawings, it should be understood that aspects of the disclosed embodiment can be embodied in many forms. Additionally, any suitable size, shape, or type of elements or materials may be used.

[0009] According to aspects of the disclosed embodiment, the automated storage and retrieval system 100 may operate in a retail distribution center or warehouse to fulfill orders received from retailers for case units, such as those described in U.S. Patent Application No. 13 / 326,674, filed December 15, 2011, the entire disclosure of which is incorporated herein by reference. For example, a case unit is a case or unit of goods that is not stored (e.g., uncontained) in a tray, on a tote, or on a pallet. In other examples, a case unit is a case or unit of goods that is contained in any suitable manner, such as in a tray, on a tote, or on a pallet. In yet another example, a case unit is a combination of uncontained and contained goods. It is noted that a case unit may include, for example, a boxed unit of goods (e.g., a case of soup cans, boxes of cereal, etc.) or individual goods that are adapted to be picked from or placed on a pallet. According to aspects of the disclosed embodiment, shipping cases for the case units (e.g., cartons, barrels, boxes, crates, jugs, or any other device suitable for holding case units) may be variable in size and may be used to hold the case units in distribution and may be configured to be palletizable for distribution. Note, for example, that when a batch or pallet of case units arrives at the storage and retrieval system, the contents of each pallet may be identical (e.g., each pallet holds a predetermined number of identical items - one pallet holds soup, another pallet holds cereal), and when the pallets leave the storage and retrieval system, the pallets may contain an appropriate number and combination of different case units that are fed, for example, to a palletizer in an assorted arrangement to form a mixed pallet (e.g., a mixed pallet, where each mixed pallet holds different types of case units - one pallet holds a combination of soup and cereal).In embodiments, the storage and retrieval systems described herein may be applied to any environment in which case units are stored and retrieved.

[0010] 1C, it is noted that, for example, when an incoming batch or pallet of case units (e.g., from a manufacturer or wholesaler) arrives at the storage and retrieval system 100 at inbound for replenishment, the contents of each pallet may be identical (e.g., each pallet holds a predetermined number of identical items - one pallet holds soup, another pallet holds cereal). As can be appreciated, the cases in such a pallet load may be substantially similar, in other words, homogenous cases (e.g., similar dimensions) and may have identical SKUs (alternatively, as discussed above, the pallet may be a "rainbow" pallet having layers formed of homogenous cases). When the pallet PAL leaves the storage and retrieval system 100 at outbound with the cases fulfilling the replenishment orders, the pallet PAL may include any suitable number and combination of different case units CU (e.g., each pallet may hold different types of case units - one pallet holds a combination of canned soup, cereal, drink cartons, cosmetics, and household cleaners). Cases combined on a single pallet may have different dimensions and / or different SKUs. In one aspect of the exemplary embodiment, and referring also to FIG. 1E, storage and retrieval system 100 may be generally configured to include an input section (including one or more input stations 160IN), a storage and sortation section 100SS (in one aspect, storage of items is optional, and in one aspect, storage and sortation section 100SS includes multi-level case storage 170, horizontal case transport 171, case buffers and vertical case transport 173), and an output section 100US (including one or more output stations 160UT), as described in further detail below.In other aspects, one or more of the case buffer 172 and vertical case transport 173 are included in the output section 100US, while in yet other aspects, the case buffer 172 and vertical case transport 173 are common to both the storage and sortation section 100SS and the output section 100US. As can be appreciated, in one aspect of the disclosed embodiment, the system 100 operating as a retail distribution center, for example, may function to receive a single pallet load of cases, break down the goods on the pallet from the single pallet load into separate case units that are individually operated by the system or separate the cases, remove and sort the different cases required by each order into corresponding groups, transport the corresponding groups of cases, and assemble into what may be referred to as a mixed case pallet load MPL. As can be appreciated, as shown in FIG. 21, in one aspect of the disclosed embodiment, the system 100 operating as, for example, a retail distribution center may function to receive a single pallet load of cases, break down the goods on the pallet from the single pallet load into separate case units that are individually operated by the system, or separate the cases, remove and sort the different cases required by each order into corresponding groups, transport the corresponding groups of cases, and sequence the corresponding groups of cases (in a manner described herein) at the operator station 160EP, where the items removed from the different case units CU and / or the different case units CU themselves are placed by the operator 1500 or any suitable automation into one or more bags, totes or other suitable containers TOT in a predetermined order sequence of the items to be removed, for example, according to instructions to fulfill one or more customer orders, where the case units CU are sequenced at the operator station 160EP according to the predetermined order sequence of the items to be removed, and it is noted that the sequencing of the case units CU described herein results in sequencing at the operator station 160EP.

[0011] The input section may be capable of breaking down a single pallet load into individual cases and transporting the cases by appropriate transport for entry into the storage and sorting section. In one embodiment, the storage and sorting section receives the individual cases, stores them in a storage area, and individually removes the required cases for transport to the output section 100US in response to instructions generated in response to orders entered into a warehouse management system, such as warehouse management system 2500. In one embodiment, the transports to the output section 100US are sequenced 174 transports. In other embodiments, the storage and sorting section receives the individual cases in response to orders entered into the warehouse management system, sorts the individual cases (e.g., utilizing buffers and interface stations described herein and generally referred to as holding stations), and transports the individual cases to the output section. Sorting and grouping of cases according to orders (e.g., order or load discharge sequence) may be performed in whole or in part by either the storage and retrieval section 100SS (also referred to herein as the storage and sorting section) or the output section 100US, or by both, at the interface between the one for convenience of explanation and sorting and grouping can be performed in a variety of ways. For example, as noted above, while in FIG. 1E the case buffer 172 and vertical case transport 173 are shown included in the storage and sorting section 100SS, in other aspects one or more of the case buffer 172 and vertical case transport 173 are included in the storage and sorting section 100SS and the output section 100US and / or are common to both the storage and sorting section 100SS and the output section 100US.The intended result is that in one aspect, the output section will assemble appropriate groupings of ordered cases, which may vary in SKU, size, etc., into a pallet load of mixed cases, for example, in the manner described in U.S. patent application Ser. No. 13 / 654,293, filed Oct. 17, 2012 (now U.S. Patent No. 8,965,559), the entire disclosure of which is incorporated herein by reference, while in another aspect, the output section will assemble appropriate groupings of ordered cases, which may vary in SKU, size, etc., into bags, totes, or other suitable containers according to a predetermined order sequence of items to be removed at an operator station (e.g., to fulfill a customer order, etc.).

[0012] In one aspect of the exemplary embodiment, the discharge section 100US produces a pallet load in what may be referred to as a structured configuration of mixed case stacks. In one aspect, the structured configuration of the pallet load described herein is representative, and in other aspects the pallet load may have any other suitable configuration. For example, the structured configuration may be any suitable predetermined configuration, such as a truck load or other suitable container, or a load container frame for holding a structural load. In one aspect, the structured configuration of the pallet load may be characterized as having several flat case layers L121-L125, L12T, at least one of which is formed from a stack of a plurality of mixed cases that are not intersecting and are free-standing and stable. The stacks of mixed cases in a given layer may have substantially the same height to form a given layer with upper and lower surfaces that may be recognized as being substantially flat, and may be in sufficient number to cover the pallet area or a desired portion of the pallet area. The layers being laid down may be oriented such that the cases in the corresponding layer straddle between the stacks in the supporting layer. Thus stabilizing the stack and correspondingly stabilizing the boundary layers of the pallet load. In defining the pallet load into an organized layer structure, the interlocking 3-D pallet loading solution is decomposed into two parts that can be stored separately: a vertical (1-D) part that breaks down the load into layers, and a horizontal (2-D) part that effectively distributes stacks of equal height to fill the pallet height of each layer. In other aspects, the mixed case load filling may be configured in any other suitable order sequence and may be loaded onto or within any suitable conveying device, such as, for example, one or more bags, totes, shopping carriages, trucks, or other suitable containers that are filled without palletization.As described below, the storage and retrieval system delivers the case units to the output section such that the two parts of the 3-D palletized load solution are decomposed, while in other aspects the storage and retrieval system delivers the case units to the output section according to a sequence to fulfill the pick sequence order of the non-palletized goods at the operator station 160EP. In one aspect, the predetermined configuration of the mixed palletized load determines the order of the case units and whether the case units provided by the sorting and retrieval section to the load building system (which may be automated or manual loading) are single case unit pick faces or combined case unit pick faces.

[0013] In accordance with an aspect of the disclosed embodiment, and referring again to FIG. 1, the automated storage and retrieval system 100 includes an input station 160IN (including a depalletizer 160PA, operator station 160EP and / or conveyor 160CA that transport items to the lift modules for entry into the storage section), an output station 160UT (including a palletizer 160PB and / or conveyor 160CB that transports case units from the lift modules for removal from the storage section), input and output vertical lift modules 150A, 150B (generally referred to as lift modules 150; although input and output lift modules are illustrated, a single lift module may be used to both transport case units into and remove case units from the storage structure), a storage structure 130, and a number of unmanned rovers or transport vehicles 110 (referred to herein as "bots"). As used herein, at least the lift module 150, storage structure 130 and bot 110 may be collectively referred to herein as the storage and sortation section described above. Also note that the depalletizer 160PA may be configured to remove case units from the pallet so that the loading station 160IN may transport the items to the lift module 150 for loading into the storage structure 130. The palletizer 160PB may be configured to place items removed from the storage structure 130 onto the pallet PAL (FIG. 1C) for delivery.

[0014] 2A, the storage structure 130 may include multiple storage rack modules RM, which are composed of high-density three-dimensional rack arrays RMA accessible from a storage or deck level 130L. Each storage level 130L includes a pick-face storage / handover space 130S (referred to herein as a storage space 130S) formed by rack modules RM, and the rack modules are arranged, for example, along a storage or retrieval aisle 130A (connected to the transfer deck 130B) that extends linearly through the rack module array RMA and provides access to the storage space 130S and the transfer deck 130B, and the bot 110 travels on the respective storage level 130L across the retrieval aisle 130A and the transfer deck 130B to transfer case units between any of the storage spaces 130S (e.g., on the level on which the bot 110 is located) of the storage structure 130 and any of the lift modules 150 (e.g., each bot 110 has access to each storage space 130S on each level and each lift module 150 on each storage level 130L). The transfer decks 130B may be positioned / arranged at different levels to define a multi-level deck (corresponding to each level 130L of the storage and retrieval system) that may be stacked one above the other or offset horizontally, such as having one transfer deck 130B at one end or side RMAE1 of the storage rack array RMA, or at several ends or sides RMAE1, RMAE2 of the storage rack array RMA, as described, for example, in U.S. patent application Ser. No. 13 / 326,674, filed December 15, 2011, the entire disclosure of which is incorporated herein by reference.

[0015] The transfer deck 130B is substantially open and configured for non-deterministic movement of the bot 110 across and along the transfer deck 130B. As can be understood, the transfer deck 130B(s) on each storage level 130L communicates with each of the pick-up aisles 130A on the respective storage level 130L. The bot 110 bidirectionally moves between the transfer deck 130B(s) and the pick-up aisles 130A on the respective storage level 130L to access the storage spaces 130S arranged on the rack shelves alongside each of the pick-up aisles 130A (e.g., as the bot 110 moves through each pick-up aisle 130A, the bot 110 may access the storage spaces 130S distributed on both sides of each aisle, such that the drive wheels 202 may have different orientations, such as the drive wheels 202 leading in the direction of movement or the drive wheels following in the direction of movement, for example, referring to FIG. 6). As mentioned above, the transfer deck(s) 130B also provide access by the bot 110 to each of the lifts 150 on each storage level 130L, which deliver and / or retrieve case units to and from each storage level 130L, and the bot 110 transfers case units between the lifts 150 and the storage space 130S. As mentioned above, also referring to FIG. 2A, in one embodiment, the storage structure 130 includes a plurality of storage rack modules RM, which are arranged in a three-dimensional rack array RMA in which the racks are arranged in the aisle 130A, and the aisle 130A is configured for the movement of the bot 110 in the aisle 130A. The transfer deck 130B has a non-deterministic transport surface on which the bot 100 moves, and the non-deterministic transport surface 130BS has two or more parallel movement lanes (e.g., high speed bot movement paths HSTP) connecting between the retrieval aisles 130A. As can be seen, the parallel travel lanes are juxtaposed along a common non-deterministic transport surface 130BS between opposing sides 130BD1, 130BD2 of the transfer deck 130B.2A, in one embodiment, the aisle 130A is joined to the transfer deck 130B on one side 130BD2 of the transfer deck 130B, while in other embodiments, the aisle is joined to two or more sides 130BD1, 130BD2 of the transfer deck 130B in a manner substantially similar to that described in U.S. Patent Application No. 13 / 326,674, filed December 15, 2011, the entire disclosure of which is previously incorporated by reference herein. As described in more detail below, the other side 130BD1 of the transfer deck 130B includes deck storage racks (e.g., interface stations TS and buffer stations BS) distributed along the other side 130BD1 of the transfer deck 130B such that at least a portion of the transfer deck is interposed between the deck storage racks and the aisle 130A. The deck storage rack is positioned along the other side 130BD1 of the transfer deck 130B so that the deck storage rack is in communication with the bots 110 from the transfer deck 130B and with the lift module 150 (e.g., the deck storage rack is accessed by the bots 110 from the transfer deck 130B and by the lift 150 to retrieve and place pick faces so that pick faces can be transported between the bots 110 and the deck storage rack, and between the deck storage rack and the lift 150, and thus between the bots 110 and the lift 150).

[0016] Each storage level 130L may include a charging station 130C for charging the on-board power source of the bot 110 on that storage level 130L, as described, for example, in U.S. patent application Ser. No. 14 / 209,086, filed March 13, 2014, and U.S. patent application Ser. No. 13 / 326,823, filed December 15, 2011 (now U.S. Patent No. 9,082,112), the disclosures of which are incorporated herein by reference in their entireties.

[0017] Bot 110 may be any suitable independently operable autonomous transport vehicle that grasps / holds and transports case units / picks faces throughout storage and retrieval system 100. In one embodiment, bot 110 is an automated, independent (e.g., free-riding) autonomous transport vehicle. Suitable examples of bots are described in U.S. Patent Application No. 13 / 326,674, filed December 15, 2011, U.S. Patent Application No. 12 / 757,312, filed April 9, 2010 (now U.S. Patent No. 8,425,173), U.S. Patent Application No. 13 / 326,423, filed December 15, 2011, U.S. Patent Application No. 13 / 326,447, filed December 15, 2011 (now U.S. Patent No. 8,965,619), U.S. Patent Application No. 13 / 326,448, filed December 15, 2011 (now U.S. Patent No. 8,965,619), U.S. Patent Application No. 13 / 326,674, filed December 15, 2011, the disclosures of which are incorporated herein by reference in their entirety, for purposes of illustration only. No. 13 / 326,505 (now U.S. Patent No. 8,696,010), U.S. Patent Application No. 13 / 327,040 (now U.S. Patent No. 9,187,244), filed December 15, 2011, U.S. Patent Application No. 13 / 326,952, filed December 15, 2011, U.S. Patent Application No. 13 / 326,993, filed December 15, 2011, U.S. Patent Application No. 14 / 486,008, filed September 15, 2014, and U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015. The bot 110 (described in further detail below) may be configured to place case units, such as the retail items described above, into one or more levels of pick-up storage in the storage structure 130 and then selectively pick up the ordered case units.

[0018] The bots 110, lift modules 150 and other suitable features of the storage and retrieval system 100 are controlled in any suitable manner, such as, for example, by one or more central system control computers (e.g., control server) 120, through any suitable network 180. In one embodiment, the network 180 is a wired network, a wireless network, or a combination of wired and wireless networks, using any suitable type and / or number of communication protocols. In one embodiment, the control server 120 includes a collection of substantially simultaneously executing programs (e.g., system management software) for substantially automatic control of the automated storage and retrieval system 100. For example, a collection of substantially simultaneously executing programs configured to manage the storage and retrieval system 100 may include, by way of example only, controlling, scheduling and monitoring all active system components, managing inventory (e.g., which case units are loaded and removed, the order in which the case units are removed, where the case units are stored) and pick faces (e.g., one or more case units that are movable as a unit and operated as a unit by the components of the storage and retrieval system), and connecting with the warehouse management system 2500. The control server 120, in one aspect, may be configured to control features of the storage and retrieval system in the manner described herein. For simplicity and ease of description, the term "case unit" is used generally herein to refer to both individual case units and pick faces (wherein a pick face is formed from one or more cases that are moved as a unit). In one aspect, the control server 120 is connected to the lift module 150 for controlling the lift module 150 as described herein.In one aspect, the lift module 150 includes a lift controller LCM connected to the control server 120, one or more of the lift controller LCM and the control server 120 controlling the lift module as described herein. In one aspect, the lift controller LCM and one or more of the control server 120 are configured to control the lift module 150 to effect the picking of two or more pick faces with a common load support platform and on-the-fly sorting of the two or more pick faces with the common load support platform as described herein. In one aspect, the lift controller LCM and one or more of the control server 120 are configured to control the lift module 150 to effect the picking of two or more pick faces with a common load support platform in an order sequence and the placement of one or more pick faces with a common load support platform in an outgoing pick face holding location in an order sequence as described herein. In one aspect, one or more of the lift controller LCM and control server 120 are configured to control the lift module 150 to provide on-the-fly sorting of two or more pick faces, where a common load support platform traverses stacked pick face holding locations in a common direction as described herein. In one aspect, one or more of the lift controller LCM and control server 120 are configured to control the lift module 150 to provide placement of two or more pick faces at an outgoing pick face holding location in one offload step, where the two or more pick faces have sorted placement at offload as described herein.

[0019] 1, 1A and 1B, the rack module array RMA of the storage structure 130 includes vertical support members 1212 and horizontal support members 1200 that define a high density automated storage array, as described in further detail below. For example, in the retrieval aisle or rack aisle 130A, rails 1200S may be attached to one or more of the vertical and horizontal support members 1212, 1200, and the rails 1200S may be configured such that the bot 110 rides along the rails 1200S through the retrieval aisle 130A. At least one of at least one side of the retrieval aisle 130A of at least one storage level 130L may have one or more storage shelves (e.g., formed by rails 1210, 1200 and slats 1210S) provided at different heights to form a plurality of shelf levels 130LS1-130LS4 (any number of levels may be provided and the retrieval aisle may be divided into sections SECA, SECB each having a different number of levels or the same number of levels) between the storage or deck levels 130L defined by the transfer deck 130B (and rails 1200S forming the aisle deck). Thus, there are a plurality of rack shelf levels 130LS1-130LS4 corresponding to each storage level 130L extending along one or more retrieval aisles 130A that communicate with the transfer deck 130B of the respective storage level 130L. As can be seen, the multiple rack shelf levels 130LS1-130LS4 provide each storage level 130L with a stack of stored case units (or layers of cases) accessible from a common deck 1200S of the respective storage level 130L (e.g., stacks of stored cases are disposed between the storage levels). In one embodiment, referring to FIG. 1D, each storage level 130L includes a single level of storage shelves for storing a single level of case units (e.g., each storage level includes a single case unit support surface CUSP), and the bot 110 is configured to transport case units to and from the storage shelves of the respective storage level 130L.

[0020] As can be appreciated, a bot 110 traversing the pick-up aisle 130A with a corresponding storage level 130L has access to each storage space 130S available on each shelf level 130LS1-130LS4 (e.g., to pick and place case units), with each shelf level 130LS1-130LS4 disposed between the storage levels 130L on one or more sides PAS1, PAS2 (see, e.g., FIG. 2A) of the pick-up aisle 130A. As discussed above, each of the storage shelf levels 130LS1-130LS4 is accessible by the bot 110 from the rails 1200S (e.g., from a common pick-up aisle deck 1200S corresponding to the transfer deck 130B on the respective storage level 130L). As can be seen in FIGS. 1A and 1B, there are one or more shelf rails 1210 spaced apart vertically (e.g., in the Z direction) from one another to form a plurality of stacked storage spaces 130S, each of which is accessible by the bot 110 from a common rail 1200S. As can be appreciated, the horizontal support members 1200 also form shelf rails (in addition to the shelf rails 1210) on which case units are placed. Here, the bot 110 includes a transfer arm 110PA having a vertical drive shaft configured to transfer case units from a common pick-up aisle deck to each of the shelf levels 130LS1-130LS2. In other embodiments, each storage level 130L includes a single level of storage shelves as shown in FIG. 1B, and the bot 110, such as the bot 110′ (substantially similar to the bot 110), is not provided with sufficient Z movement of the transfer arm 110PA to place case units on the plurality of storage shelf levels 130LS1-130LS2 (e.g., accessible from a common rail 1200S) as described above. Here, the transfer arm drive of the bot 110' includes Z movement sufficient to lift the case unit off the case unit support surface CUSP of the single level storage shelf to transfer the case unit to and from the loading area 110PL and to transfer the case unit between the transfer arm 110PA and the loading bed 110PB of the loading area 110PL.A suitable example of the bot 110' can be found, for example, in U.S. Patent Application No. 13 / 326,993, filed December 15, 2011 (U.S. Patent Application Publication No. 2012 / 0185082), the entire disclosure of which is incorporated herein by reference.

[0021] Each stacked shelf level 130LS1-130LS4 (and / or each single shelf level, as described below) of the corresponding storage level 130L defines an open, non-deterministic, two-dimensional storage surface (e.g., having a case unit support surface CUSP as shown in FIG. 1B) that facilitates dynamic allocation of pick faces both longitudinally (i.e., along the length of an aisle or coincident with the bot travel path defined by the picking aisle) and laterally (i.e., across the aisle or bot travel path relative to the depth of the rack). Dynamic allocation of pick faces and the case units that make up the pick faces may be effected, for example, by methods described in U.S. Patent No. 8,594,835, issued Nov. 26, 2013, the disclosure of which is incorporated herein by reference in its entirety. In this manner, the pick faces of case units (or totes) of variable length and width are positioned at respective two-dimensional storage positions (generally referred to herein as holding positions) on a storage shelf (e.g., on each storage shelf level 130LS1-130LS4) with minimal gaps G between adjacent stored case units / storage spaces (e.g., resulting in removal / placement of a case unit without contacting other case units stored on the shelf, see FIG. 1A). In one aspect, the storage space 130S defined by storage shelf levels 130LS1-130LS4 between the storage or deck level 130L accommodates case units of different heights, lengths, widths and / or weights at the different shelf levels 130LS1-130LS2, as described, for example, in U.S. Provisional Patent Application No. 62 / 091,162, entitled "Storage retrieval system," filed December 12, 2014, and having Attorney Docket Number 1127P015163-US(-#1), the entire disclosure of which is incorporated herein by reference.

[0022] In one aspect of the disclosed embodiment, the vertical pitch between rack shelf levels 130LS1-130LS4 (corresponding to each storage level 130L) is varied such that the heights Z1A-Z1E between the shelves are different rather than equal. In another aspect, the vertical pitch between at least some of the rack shelves is the same such that the heights Z1A-Z1E between at least some of the shelves are equal, while the vertical pitch between other shelves is different. In yet another aspect, the pitch of the rack shelf levels 130LS1-130LS4 on one storage level is a constant pitch (e.g., the rack shelf levels are substantially equally spaced in the Z direction), while the pitch of the rack shelf levels 130LS1-130LS4 on different storage levels are different constant pitches.

[0023] In one embodiment, the storage space 130S defined by storage shelf levels 130LS1-130LS4 between the storage or deck levels 130L accommodates case units of different heights, lengths, widths and / or weights at the different shelf levels 130LS1-130LS4, as described, for example, in U.S. Non-Provisional Patent Application No. 14 / 966,978, filed December 11, 2015, and U.S. Provisional Patent Application No. 62 / 091,162, filed December 12, 2014, the disclosures of which are incorporated herein by reference in their entirety. For example, still referring to FIG. 1A, the storage level 130L includes a storage section having at least one intermediate shelf 1210. In the illustrated example, one storage section includes one intermediate shelf 1210, while another storage section includes two intermediate shelves 1210 to form the shelf levels 130LS1-130LS4. In one embodiment, the pitch Z1 between storage levels 130L may be any suitable pitch, such as, for example, from about 32 inches to about 34 inches, and in other embodiments, the pitch may be greater than about 34 inches and / or less than about 32 inches. Any suitable number of shelves may be provided between decks 1200S of adjacent vertically stacked storage levels 130L, with the shelves having the same or different pitches between the shelves.

[0024] In one aspect of the disclosed embodiment, the storage or deck levels 130L (e.g., the plane along which the bot 110 moves) are arranged at any suitable predetermined pitch Z1, e.g., not an integer multiple of the intermediate shelf pitches Z1A-Z1E. In other aspects, the pitch Z1 may be an integer multiple of the intermediate shelf pitch, e.g., the shelf pitch may be substantially equal to the pitch Z1, such that the corresponding storage space has a height substantially equal to the pitch Z1. As can be appreciated, the shelf pitches Z1A-Z1E are substantially decoupled from the pitch Z1 of the storage levels 130L and correspond to the height of a typical case unit as shown in FIG. 1A. In one aspect of the disclosed embodiment, case units of different heights are dynamically allocated or distributed along each aisle in the storage space 130S with shelf heights commensurate with the height of the case units. The remaining space between the storage levels 130L is free to be used for dynamic allocation for cases of corresponding heights, both along the length of the aisle (e.g., X-direction) that corresponds to the case units stored therein, and along the case units stored therein. As can be appreciated, dynamically allocating case units having different heights onto shelves having different pitches results in layers of stored cases of different heights between storage levels 130L on either side of each retrieval aisle 130A, with each case unit being dynamically distributed along the common retrieval aisle 130A such that each case unit within each layer of stored cases is independently accessible (e.g., for retrieval / placement) by the bots in the common aisle. Because the length of each aisle may include multiple case units of different heights and each rack shelf at each shelf level may be filled by dynamic allocation / distribution (e.g., to fill the rack module array RMA space in three dimensions in length, width and height to provide a high density storage array), this case unit placement / allocation and storage shelf placement results in maximum efficiency of storage space / volume usage between storage levels 130L, and therefore maximum efficiency of the rack module array RMA, with optimized case unit SKU distribution.

[0025] 1D and 6A, each of the storage levels 130L includes a single level of storage shelves for storing a single level of case units (e.g., each storage level includes a single case unit support surface CUSP), and the bot 110 is configured to transfer case units to and from the storage shelves of each storage level 130L. For example, the bot 110' shown in FIG. 6A is substantially similar to the bot 110 described above, but the bot 110' lacks sufficient Z movement of the transfer arm 110PA to place case units on multiple storage shelf levels 130LS1-130LS4 (e.g., accessible from a common rail 1200S) as described above. Here, the transfer arm drive 250 (which may be substantially similar to one or more of drives 250A, 250B) includes sufficient Z movement to lift a case unit off of a case unit support surface CUSP of a single level storage shelf for transferring the case unit to and from the loading area 110PL and between the fingers 273 of the transfer arm 110PA and the loading bed 110PB. Suitable examples of bots 110' can be found, for example, in U.S. patent application Ser. No. 13 / 326,993, filed Dec. 15, 2011, the disclosure of which is incorporated herein by reference in its entirety.

[0026] 2A , in one aspect of the disclosed embodiment, the rack shelves 1210 (including the rack shelves formed by the rails 1200) are longitudinally partitioned (e.g., in the X direction along the length of the pick aisle 130A relative to the storage structure reference coordinate system RFE2) into SECA, SECB to form ordered or matched rack shelf sections along each pick aisle 130A. The aisle shelf sections SECA, SECB are ordered / matched relative to each other, for example, based on the pick order of the bots 110 that traverse the aisle in a common path and pick case units specified by a common order fulfillment (e.g., based on an order removal sequence). In other words, the bot 110 creates a single path (e.g., travel in a single direction) down a single or common pick aisle while picking one or more case units from the aisle rack sections SECA, SECB on a common side of the pick aisle 130A to build a pick face on the bot 110, the pick face including the case units that are arranged on the bot according to an order fill / order remove sequence as described in further detail below. The aisle rack sections SECA, SECB each include an intermediate shelf in the manner described above. In other embodiments, some of the aisle shelves do not include an intermediate shelf, while others do.

[0027] In one aspect, the rack sections SECA, SECB of the ordered aisle include different shelf pitches between sections SECA, SECB. For example, the rack section SECA of the aisle has shelves of one or more pitches, while the rack section SECB of the aisle has shelves of one or more different pitches (e.g., different from the shelf pitch of section SECA). According to aspects of the disclosed embodiment, the pitch of at least one intermediate shelf of the rack section SECA, SECB of one aisle is associated with the pitch of at least one intermediate shelf of the other of the ordered aisle rack sections SECA, SECB of the common pick-up aisle 130A. The different pitches of the intermediate shelves 1210 in the rack sections SECA, SECB of the ordered aisle are selected to be associated and to provide multiple (at least two) ordered picks (i.e., picks in order sequence) by the bot 110 according to the delivery sequence of the mixed SKU loads (e.g., pallet loading to a common pallet load) from the shelves of different pitches of the common path of the common pick-up aisle 130A. As can be appreciated, the removal of mixed loads from the storage and retrieval system 100 (e.g., for filling truck load ports / pallet loads) is sequenced in a predetermined order according to the various loads exiting the retrieval aisle (e.g., the aisle from which case units are removed for transfer to outgoing pallets), and the shelf pitch of the ordered sections SECA, SECB facilitates the bot 110 to retrieve two or more case units in an ordered sequence according to the order of the loads' removal sequence in a common retrieval aisle path (e.g., two or more case units are removed from a common retrieval aisle in a predetermined order in one path of the common retrieval aisle).The shelf pitches of different aisles of the ordered rack sections SECA, SECB are associated to improve the possibility of ordered multiple picks (picking of two or more case units from a single aisle with a single path as described above) such that multiple picks are achieved by the order processing path of each bot along each aisle, and are associated such that more than half of the cases picked up in the storage and retrieval system 100 by the bots 110 and intended for a common load output (e.g., a common pallet load) are picked up by a common bot 110 in an ordered order according to the load output sequence during a single path of the common retrieval aisle (e.g., two or more cases picked up by the bots 110 are picked from the same retrieval aisle of a single path, e.g., the bots move in a single direction through the retrieval aisle). As can be appreciated, in one aspect of the disclosed embodiment, both sides PAS1, PAS2 of the pick-up aisle 130A have ordered aisle rack sections SECA, SECB, and one ordered section may be matched with one or more sections on the same side PAS1, PAS2 of the common pick-up aisle 130A. As can be appreciated, the matched aisle rack sections may be positioned adjacent to one another or spaced apart from one another along the pick-up aisle 130A.

[0028] 2A and 2B, each transfer deck 130B or storage level 130L includes one or more lift pick face interface / transfer stations TS (referred to herein as interface stations TS) where one or more case units or totes (single or mixed case pick faces) are transferred between the lift load handling device LHD and the bots 110 on the transfer deck 130B. The interface stations TS (and buffer stations BS described herein) provide an interface between the bots 110 and at least one lift 150 on each transfer deck 130B to effect the transfer of pick faces between the bots 110 and at least one lift 150. One or more lift interface stations TS of one or more of the transfer decks or storage levels 130L have multiple load stations MLS for positioning / buffering loads CU (such as case units) for pick-up by the lift 150B. As described herein, in one aspect, each load is a pick face of one or more case units that are picked / placed as a unit at the multiple load station MLS by one or more of the load handling devices LHD of the bot 110 and the lift 150B. In one aspect, the case units of each load / pick face are placed as a unit in the load outlet, and in other aspects are distributed within the load outlet. As described herein, each lift 150 includes a carriage 4001 having a common multiple load platform configured for lifting / lowering in one aspect to provide for the picking of multiple loads (e.g., from a common interface station TS with a common / single load handling device LHD or with multiple independent load handling devices LHD), and in another aspect to provide for the picking of multiple independent loads (e.g., from separate deck level interface stations TS, etc.) in a single lift pass.As can be appreciated, in one aspect, multiple loads (e.g., multiple pick faces carried together as a single load or unit) are positioned at one or more of the interface stations TS (or buffer stations BS) for removal by the lift 150.

[0029] The interface station TS is located on the opposite side of the transfer deck 130B from the pick-up aisle 130A and the rack module RM, such that the transfer deck 130B is interposed between the pick-up aisle and each interface station TS. As described above, each bot 110 on each pick-up level 130L has access to each storage location 130S, each pick-up aisle 130A, and each lift 150 on each storage level 130L, so that each bot 110 also has access to each interface station TS on the respective level 130L. In one embodiment, the interface station is offset from the high-speed bot travel path HSTP along the transfer deck 130B such that the bot 110's access to the interface station TS is non-deterministic with respect to the bot's speed on the high-speed travel path HSTP. In this way, each bot 110 can move a case unit (or pick face, e.g., one or more cases built by the bot) from each interface station TS to each storage space 130S according to the deck level, and vice versa.

[0030] As an example, in one embodiment, the pick face constructed (e.g., in the manner described above) by the bot 110 to be transferred (e.g., placed) to, for example, the interface station TS (and / or the buffer station BS) is not identical to the pick face removed from the interface station TS (and / or the buffer station BS) by the lift 150. For example, referring to FIG. 9, the bot 110 forms a first pick face including individual pick faces 7 and 5 from the storage space 130S of the buffer BS in the rack module RM (e.g., FIG. 2A) and / or on the transfer deck 130B (FIGS. 10-10E and FIG. 19, block 1900). The bot 110 transfers and places the first pick face, for example, on the shelf 7000B (FIG. 9) of the interface station TS for transfer to the lift 150 (FIG. 19, block 1910). As can be appreciated, in this example, the individual pick faces 5, 7 (e.g., forming a first pick face) are placed on a common shelf 7000B for illustrative purposes only, but in other embodiments, the individual pick faces 5, 7 are placed on different shelves 7000A-7000F (FIG. 9) such that the pick face placed on the shelf by the bot 110 is different from the first pick face but includes at least one common case unit with the first pick face. For example, the first pick face is decomposed such that a different pick face including the individual pick face 5 is placed on shelf 7000B, while another different pick face including the individual pick face 7 is placed on, for example, shelf 7000H. A lift such as lift 150B1 retrieves a second pick face from one or more shelves 7000A-7000F (e.g., common to both the bot 110 and lift 150B1) of the transfer station TS (FIG. 19, block 1920). Here, the second pick face is different from the first pick face but includes at least one of the individual pick faces 5, 7 such that at least one case unit is common between the first pick face and the second pick face.

[0031] Similarly, in one embodiment, the pick face transferred (e.g., placed) by the inbound lift 150 (see lift 150A in FIG. 1 ) to, for example, the interface station TS (and / or buffer station BS) is not the same as the pick face removed by the bot 110 from the interface station TS (and / or buffer station BS). For example, referring to FIG. 9A , a first pick face is transferred by the inbound conveyor 160CB from the input station(s) 160IN to one or more lifts 150A1, 150A2, i.e., each of the lifts 150A1, 150A2 removes a first pick face ( FIG. 20 , block 2000). In this example, one of the first pick faces, such as the first pick face removed by lift 150A1, includes a combination of individual pick faces 5, 7, while the other first pick face removed by lift 150A2 includes a combination of individual pick faces 20, 22. The lift 150 may effect sorting of incoming case flow by placing one or more pick faces held on the common shelf of the lift at a first interface station and maintaining other case units on the common shelf of the lift for placement at another, different interface station. For example, the lift 150A1 places each of the first pick faces 5, 7 on shelf 7000B of the interface station TS, while the lift 150A2 places each of the other first pick faces 20, 22 on shelf 7000H of another interface station TS on the same storage level 130L (FIG. 20, block 2010). In other embodiments, the first pick faces 5, 7 may be broken down into at least one second pick face, and the pick face 5 (e.g., the second pick face) may be placed on shelf 7000B, while the pick face 7 (e.g., the third pick face) is placed on shelf 7000D (FIG. 20, block 2015).In one embodiment, the lift 150 may transport one or more case units from one storage level to another, e.g., from shelf 7000A to shelf 7000D, and the bot 110 retrieves the transported case units (transported from the storage level corresponding to shelf 7000A) and places the transported case units in a storage space on the storage level corresponding to shelf 7000D. The bot 110 builds or retrieves from the interface station TS (one or more) second pick faces such that the first pick face (one or more) placed on the shelf (one or more) 7000B, 7000H (e.g., common to the bot 110 and the respective lift 150A) by the lift 150A1, 150A2 is different from the second pick face, but the second pick face includes at least one case unit in common with the first pick face ( FIG. 20 , block 2020). For example, the first pick faces 5, 7 may be disassembled such that a different pick face, including individual pick face 5 (or individual pick face 7), is retrieved by the bot 110, and / or the other first pick faces 20, 22 may be disassembled such that a different pick face, including individual pick face 20 (or individual pick face 22), is retrieved by the bot 110. Here, the second pick face is different from the first pick face, but includes at least one of the individual pick faces of the first pick face such that at least one case unit is common between the first pick face and the second pick face. As can be understood, the second pick face may be disassembled by the bot such that the pick face placed on at least one storage shelf using 110 is different from the second pick face, and at least one case unit is common between the second pick face and the pick face placed on at least one storage shelf.As can be appreciated, for inbound transfers, the pick faces 5, 7 are transferred as a unit from the lifts 150A1, 150A2, and the pick faces 5, 7 (which may include combined case units / totes) at any one of the interface stations TS may be distributed such that one or more of the case units / totes in the pick faces 5, 7 are transferred to separate storage rack locations (e.g., separate storage spaces 130S) when transported by the bot 110 to the storage array. Similarly, for outbound transfers (described in more detail below) from the storage rack to a load output, such as a palletized loading cell or truck load output, the combined cases / totes of the pick faces 5, 7 at any of the interface stations TS may be distributed within the load output. In one aspect, distribution of the case units / totes at the load output is effected by the lifts transferring the cases / totes from the combined pick faces in a desired sequence associated with a given load output command or sequence. Similarly, each of the multiple loads carried by the load handling device LHD may be transferred in a desired sequence associated with a given load delivery section. For example, in one embodiment, the load handling device LHD of lift 150B delivers multiple loads (e.g., of a common pick face) in a single placement step in an order sequence for unloading (in one embodiment, lift 150B removes case units in a single removal step in an order sequence). In another embodiment, lift 150B removes case units in multiple removal steps to provide an order sequence of case units. In one embodiment, at least one pick face of a combined pick face carried on a common load handling device is different (e.g., has a different configuration) from other pick faces of the combined pick faces.

[0032] In one embodiment, the interface station TS is configured for passive transfer (e.g., handover) of case units (and / or pick faces) between the bot 110 and the load handling device LHD of the lift 150 (e.g., the interface station TS does not have moving parts for transporting case units), as described in further detail below. For example, referring also to FIG. 2B, the interface station TS and / or buffer station BS include one or more stacked levels TL1, TL2 of a transport rack shelf RTS, which in one embodiment are similar to the storage shelves described above (e.g., each formed by rails 1210, 1200 and slats 1210S) (e.g., to take advantage of the lifting ability of the bot 110 relative to the stacked rack shelves RTS), such that handover (e.g., picking and placing) of the bot 110 occurs in a passive manner substantially similar to the manner in which case units or totes are transferred to and from the shelves between the bot 110 and the storage space 130S (as described herein). In one embodiment, the buffer stations BS on one or more of the stacked levels TL1, TL2 also function as a handoff / interface station for the load handling device LHD of the lift 150. In one embodiment, when a bot 110, such as bot 110', is configured for the transfer of case units to a single level 130L of a storage shelf, the interface station TS and / or buffer station BS also include a single level of transport rack shelves (e.g., substantially similar to the storage rack shelves of the storage level 130L described above with respect to FIG. 1D). As can be appreciated, the operation of a storage and retrieval system including bot 110' providing a single level of storage and transport shelves is substantially similar to that described herein.As can also be appreciated, the handover (e.g., picking and placing) of the load handling devices LHD of case units (e.g., individual case units or pick faces) and totes to the stacked rack shelves RTS (and / or single level rack shelves) occurs in a passive manner substantially similar to the manner in which case units or totes are transferred to and from the shelves between the bot 110 and the storage space 130S (as described herein). In other embodiments, the shelves may include any suitable transfer arm (the transfer arm may be substantially similar to the transfer arm 110PA of the bot 110 shown in FIG. 6 and / or the transfer arm of the load handling device shown in FIGS. 4A-5B, although the Z-direction movement may be omitted if the transfer arm is incorporated into the shelf of the interface station TS) for picking and placing case units or totes from one or more of the load handling devices LHD of the bot 110 and lift 150. Suitable examples of interface stations with active transfer arms are described, for example, in U.S. patent application Ser. No. 12 / 757,354, filed Apr. 9, 2010, the entire disclosure of which is incorporated herein by reference.

[0033] In one embodiment, the positioning of the bot 110 relative to the interface station TS occurs in a manner substantially similar to the positioning of the bot relative to the storage space 130S. For example, in one embodiment, the positioning of the bot 110 relative to the storage space 130S and the interface station TS occurs in a manner substantially similar to that described in U.S. Patent Application No. 13 / 327,035 (now U.S. Patent No. 9,008,884) filed December 15, 2011 and U.S. Patent Application No. 13 / 608,877 (now U.S. Patent No. 8,954,188) filed September 10, 2012, the entire disclosures of which are incorporated herein by reference. For example, referring to Figures 1 and 1B, the bot 110 includes one or more sensors 110S that detect slats 1210S and / or positioning features 130F (such as openings, reflective surfaces, RFID tags, etc.) disposed on / within the rail 1200. The slats and / or positioning features 130F are positioned to determine the position of the bot 110 within the storage and retrieval system, for example, relative to the storage space and / or interface station TS. In one embodiment, the bot 110 includes a controller 110C that, for example, counts the slats 1210S to at least partially determine the position of the bot 110 within the storage and retrieval system 100. In other embodiments, the positioning features 130F may be positioned to form an absolute or incremental encoder that, when detected by the bot 110, provides a position determination of the bot 110 within the storage and retrieval system 100.

[0034] As can be seen, referring to FIG. 2B , the transfer rack shelves RTS of each interface / transfer station TS define a multiple load station MLS (e.g., having one or more storage case holding positions for holding a corresponding number of case units or totes) on a common transfer rack shelf RTS. As described above, each load of the multiple load station is a single case unit / tote or a pick face of multiple cases (e.g., having multiple case units / totes moved as a unit) that is picked up and placed by either a bot or a load handling device LHD. As can be seen, the above-mentioned bot positioning enables the bot 110 to position itself relative to the multiple load station MLS to pick up and place a case unit / tote and pick face from a given one of the holding positions of the multiple load station MLS. The interface / transfer station TS defines a buffer where incoming and / or outgoing case units / totes and pick faces are temporarily stored as they are transferred between the bot 110 and the load handling device LHD of the lift 150.

[0035] In one embodiment, one or more peripheral pick face buffer / transfer stations BS (substantially similar to the interface stations TS and referred to herein as buffer stations BS) are also disposed on the transfer deck 130B opposite the pick-up aisle 130A and the rack modules RM, such that the transfer deck 130B is interposed between the pick-up aisle and each buffer station BS. The peripheral buffer stations BS are interspersed among the interface stations TS or, in one embodiment, are in line with the interface stations TS, as shown in FIGS. 2A and 2B. In one embodiment, the peripheral buffer stations BS are formed by the rails 1210, 1200 and slats 1210S and are an extension (albeit a separate section) of the interface stations TS (e.g., the interface stations and the peripheral buffer stations are formed by a common rail 1210, 1200). Thus, the peripheral buffer stations BS, in one embodiment, include one or more stacked levels TL1, TL2 of transport rack shelves RTS as described above with respect to the interface stations TS, while in other embodiments, the buffer stations include a single level of transport rack shelves. The peripheral buffer stations BS define buffers where case units / totes and / or pick faces are temporarily stored for any suitable reason, such as when they are being transferred from one bot 110 to another different bot 110 on the same storage level 130L as described in further detail below. As can be appreciated, in one embodiment, the peripheral buffer stations BS are located in any suitable location of the storage and retrieval system, including anywhere in the retrieval aisle 130A and along the transfer deck 130B. As can be appreciated, the case units located at the buffer stations BS are transferred to the interface station TS in one embodiment by the bot 110, and in other embodiments by any suitable conveyor connecting the buffer stations BS to the interface station TS.In one aspect, when a case unit is transported by a bot 110 from a buffer station BS to an interface station TS, the transport is a timely transport, for example, such that the bot 110 travels along a transport deck on a route for another task (e.g., transporting a pick face to storage, sorting the pick face, transporting a pick face from storage, etc.) and travels past the buffer station BS, stops to retrieve a pick face from the buffer station BS, and transports the pick face to the interface station TS during the process of performing another task.

[0036] Still referring to Figures 2A and 2B, in one embodiment, the interface stations TS are arranged along the transfer deck 130B in a manner similar to a parking space on the side of a road so that the bot 110 "parallel parks" at a given interface station TS to transfer case units to and from one or more shelves RTS at one or more levels TL1, TL2 of the interface station TS. In one embodiment, the transfer orientation of the bot 110 at the interface station TS (e.g., when parallel parked) is the same as the orientation when the bot 110 is moving along the high-speed bot transport path HSTP (e.g., the interface station is approximately parallel to the bot movement direction of the transfer deck and / or the side of the transfer deck on which the lift 150 is located). The interaction of the bot 110 with the peripheral buffer station BS also occurs by parallel parking such that the transfer orientation of the bot 110 at the peripheral buffer station BS (e.g., when parallel parked) is the same as the orientation when the bot 110 is moving along the high-speed bot transport path HSTP.

[0037] In another embodiment, referring to FIGS. 3A and 3B, at least the interface station TS is disposed on an extension or pier 130BD extending from the transfer deck 130B. In one embodiment, the pier 130BD is similar to a pick-up aisle along which the bot 110 moves along a rail 1200S secured to the horizontal support member 1200 (in a manner substantially similar to that described above). In other embodiments, the movement surface of the pier 130BD may be substantially similar to the movement surface of the transfer deck 130B. Each pier 130BD is disposed on a side of the transfer deck 130B, such as the side opposite the pick-up aisle 130A and the rack module RM, such that the transfer deck 130B is interposed between the pick-up aisle and each pier 130BD. The pier 130BD extends from the transfer deck at a non-zero angle relative to at least a portion of the high speed bot transport path HSTP. In other embodiments, the pier 130BD extends from any suitable portion of the transfer deck 130B, including ends 130BE1, 130BE2 of the transfer deck 130BD. As can be appreciated, peripheral buffer stations BSD (substantially similar to the peripheral buffer stations BS described above) may also be disposed along at least a portion of the pier 130BD.

[0038] 4A, 4B and 5, as noted above, in one embodiment the interface station TS is a passive station and the load transfer or handling device LHD of the lifts 150A, 150B has an active transfer arm or pick head 4000A, 4000B. In one embodiment, the lift 150 in communication between the input and output conveyors 160CA, 160CB and one or more of the interface station(s) TS (which in one embodiment include the stacked transfer rack shelves RTS) of the stacked deck level 130C is a reciprocating lift (e.g., the lift moves linearly along a single linear path, bidirectionally in the Z direction (relative to the lift reference frame REFL shown in FIG. 5)). The lift 150 is not limited in speed of movement in the Z direction and is a high speed lift (rather than a continuous motion or paternoster type lift) and the speed or rate of transport of the lift is not a limiting factor in the transport of case units to and from the storage and retrieval system. For example, the rate of transport of case units by the lift 150 is substantially equal to the rate of transport of case units by the bot 110. As can be appreciated, in one aspect, the loading and unloading lifts 150A, 150B are described as vertically reciprocating lifts, but in other aspects, the loading and unloading lifts 150A, 150B are any suitable pick face transport system for transporting case pick faces to and from the storage structure 130. For example, in other embodiments, the loading and unloading lift modules 150A, 150B are one or more of a reciprocating lift, any suitable automated material handling system, conveyor, bot, turntable, roller conveyor, multi-level conveyor (e.g., a paternoster conveyor) operating synchronously or asynchronously.

[0039] As described herein, the lift 150 is arranged to traverse and connect two or more levels 130L of the multi-level transfer deck 130B and to raise and lower pick faces from the multi-level transfer deck 130B. As described herein, for example, multiple loads placed at an interface station TS are removed using the load handling device LHD of the lift 150 and transported by the lift 150 in a single pass / traverse of the multiple transfer deck levels 130B to an unloading conveyor station, such as the outgoing conveyor 160CB. As noted herein, in one aspect, removal of the multiple loads is a common removal from a common interface station TS (effected with a common load handling device LHD or by multiple load handling devices LHD) to be effected in a single stop of the lift. In other embodiments, multiple loads are removed from different interface stations TS on different levels 130L of the multi-level transfer deck 130B, thus within one pass / traversal of the multiple deck levels (e.g., without a change in lift travel direction and / or cycling), but with multiple stops of the lift. As described further herein, the case loads / pick faces delivered by the lifts 150 to the unloading stations are considered to form a case load stream (e.g., each lift 150 creates one case load stream).

[0040] 4A-5B, in one embodiment, a pick head (such as pick head 4000A, 4000B, 4000C, 4000D) of each lift 150 includes a multi-load (e.g., a single load or multiple pick faces carried together as a unit) platform (e.g., load handling device LHD) configured for lifting / lowering a common multiple load (e.g., to multiple levels 130L of a storage and retrieval system). In one embodiment, pick heads 4000A, 4000B, 4000C, 4000D provide for the retrieval of multiple loads (e.g., from a common interface station with a common / single load handling device LHD or with multiple independently operable load handling devices LHDs). In another embodiment, pick heads 4000A, 4000B, 4000C, 4000D provide for the picking of multiple independent loads (such as from separate interface stations TS located on separate levels 130L of the storage and retrieval system) in a single pass / traverse towards an unloading conveyor station(s) (such as, for example, output conveyor 160CB, FIG. 1), or any other suitable pick face holding / transport station. Accordingly, multiple loads are positioned at each of the interface stations TS, or in other embodiments, at one or more of the interface stations TS, for pick-up by lift(s) 150. As can be appreciated, the multiple load(s) at each or any of the interface stations TS are picked up by the load handling device LHD of the lift 150 and transported by the lift 150, for example, to the output conveyor 160CB of the output station(s) 160UT, or other suitable pick face holding / transport station, in a single pass / traverse of the pick heads 4000A, 4000B relative to the level 130L of the storage and retrieval system.As noted above, in one embodiment, removal of multiple loads is a common removal from a common interface station TS (either with a common load handling device or by multiple independent load handling devices LHD such that removal of multiple loads is effected in a single stop of the removal heads 4000A, 4000B). In other embodiments, removal of multiple loads is effected from separate interface stations TS at separate levels 130L of the storage and removal system, and thus in multiple stops (but within a single pass / traverse, e.g., without a change in direction or cycling of the removal heads 4000A, 4000B).

[0041] In one embodiment, the inbound lift module 150A and the outbound lift module 150B have different types of pick heads (as described below), while in other embodiments, the inbound lift module 150A and the outbound lift module 150B have the same type of pick head, similar to one of the pick heads described below (e.g., both lifts 150A, 150B have pick head 4000A, or both lifts 150A, 150B have pick head 4000B). For example, both the inbound and outbound lift modules 150A, 150B have a vertical mast 4002 along which the slide 4001 travels (one mast is shown, but in other embodiments there are multiple masts). The mast(s) 4002 span between a base level BL (FIG. 2B), such as where the in- and out-conveyors 160CA, 160CB of the in- and out-stations 160IN, 160UT are located, and any desired deck or storage level 130L of the multi-level storage array. One or more carriages, or one or more slides 4001, move along the mast(s) 4002 under the propulsive force of any suitable drive unit 4002D (e.g., connected to the control server 120) configured to raise or lower the slides (and pick heads 4000A, 4000B attached thereto) between the base level BL and a desired interface station shelf at the desired storage level 130L. The drive unit 4002D is one or more of a chain drive, belt drive, screw drive, linear actuator, solid state drive, or any other drive capable of driving the slide(s) and the pick-up heads 4000A, 4000B mounted thereon linearly along the mast(s) 4002.

[0042] As can be appreciated, the lift 150 includes any suitable pick head positioning system for positioning the pick head(s) 4000A, 4000B relative to the interface station TS shelves. For example, any suitable encoder or position sensor SENS is provided that provides position measurement of the pick head(s) 4000A, 4000B relative to the interface station TS shelves and the inbound / outbound conveyors 160CA, 160CB along with the control server 120. For example, the control server 120 provides control signals to the lift drives 4002D, 4005, 4005A. The control server 120 also receives signals from the position sensor SENS as the pick head(s) move along the mast 4002 and determines the position of the pick head relative to the interface station TS shelves based on the signals. Based on the signal of the sensor SENS, the control server 120 causes the removal head(s) to stop at a predetermined interface station shelf and causes the extension of the load handling device LHD, as described in more detail below, to remove or place one or more case units from or on the interface station TS shelf.

[0043] As described above, the input lift module(s) 150A includes a pick head 4000A that is movable relative to the mast(s) 4002, such as by being attached to the slide 4001 such that the pick head 4000A moves with the slide(s) 4001 as the slide(s) move. In this embodiment, the pick head 4000A includes a pick head or effector, referred to herein as a load handling device LHDA, having one or more tines or fingers 4273 attached to a base member 4272 to form a platform PFM for receiving a load. The platform PFM forms a load support having a common elevator configured to hold one or more pick faces on the common elevator of the platform PFM. In one embodiment, the common elevator is a substantially flat common surface, while in other embodiments, the common elevator includes stacked shelves or effectors with a common pick and place lift position for the lifts such that the lifts can pick and place all loads at once with one stop of lift lift (e.g., as shown in FIG. 5C, one or more of pick heads 4000A, 4000B includes stacked shelves or effectors LHDA). As can be appreciated, while stacked effectors of pick head 4000A are illustrated for lift 150A, in one embodiment, one or more effectors LHDA, LHDB of pick head 4000B of lift 150B include stacked effectors. The fingers 4273 are configured to pass through or between the slats 1210S of the interface station TS shelf to transfer one or more case units between the load handling device LHD and the shelf (as described in more detail below). The base member 4272 is movably mounted to one or more rails 4360S of the frame 4200, which in turn are mounted to the slide 4001.Any suitable drive unit 4005 (substantially similar in shape to drive 4002D, but not in capacity since drive 4005 may be smaller than drive 4002D), such as a belt drive, chain drive, screw drive, gear drive, etc., is mounted to the frame 4200 and coupled to the base member 4272 for driving (with finger(s) or effector LHDA) the base member 4272 in the direction of arrow 4050 (e.g., Y direction relative to lift reference coordinate system REFL). The load platform PFM includes one or more load stations LST1-LST3, each positioned to hold case unit(s) / tote(s) or pick face(s) thereon. In one embodiment, each platform PFM is illustrated with three load stations, but in other embodiments, the platform has more or less than three load stations. Each of the case unit / tote or pick faces in one or more load stations LST1-LST3 is transferred to or from lift 150 as a whole, however, if there are multiple case units / totes (e.g., pick faces) in a load station, in one aspect the pick face is disassembled such that one or more case units forming the pick face are distributed into a different section of storage level 130L than the other case unit(s) of the pick face, although it should be understood that in other aspects the pick face may be positioned as a whole within storage space 130S in the manner described herein.

[0044] The outgoing lift module 150B also includes a pick head 4000B that is attached to the slide 4001 such that the pick head 4000B moves with the slide 4001 as the slide moves. In this embodiment, the pick head 4000B includes one or more pick head portions or effectors (e.g., transfer arms) LHDA, LHDB (each substantially similar to the pick head 4000A), each having one or more tines or fingers 4273 attached to a respective base member 4272A. Each base member 4272A is movably attached to one or more rails 4360SA of a frame 4200A that is in turn attached to the slide 4001. Any suitable drive unit 4005A, such as a belt drive, chain drive, screw drive, gear drive, etc., is mounted to the frame 4200A and coupled to each base member 4272A (with fingers) for driving the respective base member 4272A in the direction of arrow 4050 (each effector having its own drive unit such that each effector is independently movable in the direction of arrow 4050). Although two effectors LHDA, LHDB are illustrated on the pick head 4000B, the pick head 4000B may include any suitable number of effectors corresponding, for example, to the number of case unit / pick face holding positions of the interface station TS such that case units / pick faces may be individually picked from the interface station TS as described in further detail below.

[0045] In one embodiment, referring to FIG. 5A, one or more of the loading and unloading lifts 150 include multiple pick-up heads 4000C, 4000D, each mounted to a corresponding carriage or slide 4001A, 4000B. Each of the slides 4001A, 4001B (and the pick-up heads mounted thereto) is mounted to a mast 4002 such that it is independently movable in the Z direction by a respective drive 4002DA, 4002DB (substantially similar to the drive 4002D described above). While each pick-up head 4000C, 4000D shown in FIG. 5A includes a single load handling device, it should be understood that in other embodiments, one or more of the pick-up heads 4000C, 4000D include multiple load handling devices that are individually actuated in a manner similar to the pick-up head 4000B. As can be appreciated, it is desirable to provide suitable clearance between each of the slides 4001A, 4001B and the removal head(s) mounted thereon so that each removal head is provided with a full stroke of movement along the mast 4002 (e.g., from the base level BL to, for example, an interface station shelf at the top storage level 130L).

[0046] In another embodiment, as described above, each load handling device of the lifts 150A, 150B is configured to sort one or more case units located on the load handling device to build a pick face on the load handling device. For example, referring to FIG. 5B, the carriage 4200B includes a frame 4110F having a load section 4110PL. The load section 4110PL of the load handling device LHD includes a load bed 4110PB, a fence or datum member 4110PF, a transfer arm LHDA, and a pusher bar or member 4110PR. In one aspect, the loading bed 4110PB includes one or more rollers 4110RL mounted on the frame 110F to be generally parallel to the fingers 4273A-4273E, and one or more case units carried in the loading section 110PL are movable in the X direction (e.g., to align the case units laterally, not front-to-back, in the Y direction relative to the lift reference coordinate system, e.g., defined by the extension direction of the transfer arm LHDA, as described below) to position the case units in a predetermined position in the loading section 4110PL and / or relative to other case units in the loading section 4110PL. In one aspect, the rollers 4110RL may be driven (e.g., rotated about their respective axes) by any suitable motor to move the case units in the loading section 4110PL. In another aspect, the load handling device LHD includes one or more movable lateral alignment pusher bars (not shown) for pushing the case unit(s) over rollers 4110RL to move the case unit(s) into position along the X direction within the loading section 4110PL. The movable lateral alignment pusher bars may be substantially similar to those described, for example, in U.S. patent application Ser. No. 13 / 326,952, filed Dec. 15, 2011, the entire disclosure of which has been previously incorporated by reference herein.The pusher bar 4110PR, together with the fence 4110PF and / or the removal head 4270 of the transfer arm LDHA, is movable in the Y direction relative to the lift reference coordinate system REFL to provide fore-aft alignment of the case unit(s) within the load area 4110PL in the manner described in U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, the entire disclosure of which is already incorporated by reference herein.

[0047] 5B, case units are placed on and removed from the load bed 4110PB using the transfer arm LHDA. The transfer arm LHDA includes a lift mechanism or unit 5000 located substantially within the loading section 4110PL, as described, for example, in U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, the entire disclosure of which is already incorporated herein by reference. The lift mechanism 5000 provides both coarse and fine positioning of pick faces carried by the load handling device LHD and lifted into position within the storage structure 130, in addition to or in lieu of Z-directional movement of the carriage 4200B, for removing and / or placing pick faces and / or individual case units to and from shelves of the interface station TS.

[0048] The lift mechanism 5000 is configured to perform combined robotic axis movements (e.g., combined substantially simultaneous movements of the pusher bar 4110PR, the lift mechanism 5000, the pick head extension and the front / rear alignment mechanism) so that different / multiple SKUs or multiple pick loads can be handled by the lift 150. In one embodiment, the operation of the lift mechanism 5000 is independent of the operation of the pusher bar 4110PR as described below. Decoupling the axes of the lift mechanism 5000 and the pusher bar 4110PR results in a combined pick / place sequence, which results in reduced pick / place cycle times, increased throughput of the storage and pick system, and / or increased storage density of the storage and pick system as described above. For example, the lift mechanism 5000 provides for lifting case units from the load bed 4110PL of the load handling device LHD to allow the case units to be sorted and aligned in position on the load bed 41110PL and onto the transfer arm LHDA. In one aspect, the case units are lowered onto the load bed if sorting or alignment is desired, or the transfer arm LHDA may remain at least partially elevated to allow the arm to extend and retract to remove / place case units to / from the interface station TS, for example, without a secondary elevation of the transfer arm LHDA above the fence 4110PF in addition to the movement of the load handling device LHD back and forth along the mast(s) 4002.

[0049] The lift mechanism may be configured in any suitable manner such that the pick head 4270 of the load handling device LHD moves bidirectionally (e.g., reciprocally) along the Z axis (e.g., in the Z direction). In one embodiment, the lift mechanism 5000 includes a mast 5000M, and the pick head 4270 is movably mounted to the mast 4200M in any suitable manner. The mast 4200M is movably mounted to the frame 4110F in any suitable manner such that it is movable along the Y direction. In one embodiment, the frame includes a guide rail 4360S to which the mast 4200M is slidably mounted. The transfer arm drive 4005 may be mounted to the frame to provide movement of the transfer arm LHDA along at least the Y and Z directions. In one embodiment, the transfer arm drive 4005 includes an extension motor 4301 and a lift motor 4302. The extension motor 4301 may be mounted to the frame 4110F and may be coupled to the mast 4200M in any suitable manner, such as a belt and pulley transmission 4260A, a screw drive transmission (not shown) and / or a gear drive transmission (not shown). The lift motor 4302 may be mounted to the mast 4200M and may be coupled to the pick head 4270 in any suitable manner, such as a belt and pulley transmission 4271, a screw drive transmission (not shown) and / or a gear drive transmission (not shown). As an example, the mast 4200M includes a guide, such as a guide rail 4280, and the pick head 4270 is mounted along the guide rail 4280 for guided movement in the Z direction along the guide rail 4280. In other embodiments, the pick head 4270 is mounted to the mast in any suitable manner for guided movement in the Z direction. With respect to the transmission, in other embodiments, any suitable linear actuator is used to move the pick head in the Z direction. The transmission 260A for the extension motor 301 is substantially similar to that described herein with respect to the transmission 271.

[0050] Still referring to FIG. 5B, the pick head 4270 of the load handling device LHD transfers case units between the load handling device LHD and the interface station TS (e.g., FIG. 2A), or in other embodiments directly between the bot 110 and the lift module 150. In one embodiment, the pick head 4270 includes a base member 4200B1, one or more tines or fingers 4273A-4273E, and one or more actuators 4274A, 4274B. The base member 4200B1 is attached to the mast 4200M as described above so as to ride along the guide rail 4280. The one or more tines 4273A-4273E are attached to the base member 4200B1 at their proximal ends such that their distal (e.g., free) ends are cantilevered from the base member 4200B1. Referring again to FIG. 1B, the tines 4273A-4273E are configured for insertion between the slats 1210S that form the case unit support surface CUSP of the shelf of the interface station TS.

[0051] One or more of the tines 4273A-4273E are movably mounted to the base member 4200B1 (such as on slide / guide rails similar to those described above) such that they are movable in the Z direction. In other embodiments, any number of tines are mounted to the base member 4200B1, but in the embodiment shown in the drawings, for example, five tines 4273A-4273E are mounted to the base member 4200B1. While any number of the tines 4273A-4273E are movably mounted to the base member 4200B1, in the embodiment shown in the drawings, for example, the outermost tines 4273A, 4273E (with respect to the centerline CL of the pick head 4270) are movably mounted to the base member 4200B1, while the remaining tines 4273B-4273D are immovable relative to the base member 4200B1.

[0052] In this embodiment, the pick head 4270 uses only three tines 4273B-4273D to transfer smaller sized case units (and / or groups of case units) to and from the load handling apparatus LHD, and five tines 4273A-4273E to transfer larger sized case units (and / or groups of case units) to and from the load handling apparatus LHD. In other embodiments, fewer than three tines are used to transfer smaller sized case units (e.g., when three or more tines are movably attached to the base member 4200B1). For example, in one embodiment, all but one of the tines 4273A-4273E are movably mounted to the base member 4200B1 such that the smallest case unit being transferred to and from the load handling device has a width that is about the distance X1 between the slats 1210S, e.g., without interfering with other case units on a shelf at the interface station (see FIG. 1B).

[0053] The non-movable tines 4273B-4273D define the pick surface SP of the pick head 4270 and are used when transporting case units (and / or pick faces) of all sizes, while the movable tines 4273A, 4273E are selectively raised and lowered (e.g., in the Z direction by actuators 274A, 274B) relative to the non-movable tines 4273B-4273D to transport larger case units (and / or pick faces). Still referring to FIG. 5B, an example is shown in which all of the tines 4273A-4273E are positioned such that the case unit support surface SF of each tine 4273A-4273E coincides with the pick-up surface SP of the pick-up head 4270, however, as can be appreciated, the case unit support surfaces SF of the tines 4273A, 4273E are offset (e.g., downward) from the pick-up surface SP, and the two end tines 4273A, 4273E are movable to be positioned lower (e.g., in the Z direction) relative to the other tines 4273B-4273D so that the tines 4273A, 4273E do not contact one or more case units gripped by the pick-up head 4270 and do not interfere with unpicked case units that are positioned in predetermined case unit holding positions on the shelf of the interface station TS.

[0054] Movement of the tines 4273A-4273E in the Z direction is effected by one or more actuators 4274A, 4274B mounted to the transfer arm LHDA at any suitable location. In one embodiment, the one or more actuators 4274A, 4274B are mounted to the base member 4200B1 of the pick head 4270. The one or more actuators are any suitable actuators, such as linear actuators, capable of moving one or more tines 4273A-4273E in the Z direction. For example, in the embodiment shown in FIG. 5B, there is one actuator 4274A, 4274B for each of the moveable tines 4273A, 4273E such that each moveable tine is independently moveable in the Z direction. In other embodiments, one actuator may be coupled to two or more moveable tines such that the two or more tines move as a unit in the Z direction.

[0055] As can be appreciated, movably mounting one or more tines 4273A-4273E on the base member 4200B1 of the pick head 4270 provides full support for larger case units and / or pick faces on the pick head 4270 while also providing the ability to pick and place smaller case units, for example, without interfering with other case units located on a shelf at the interface station TS. The ability to pick and place case units of various sizes without interfering with other case units at the interface station reduces the size of the gaps G (FIG. 9) between case units on the shelf at the interface station.

[0056] Referring again to FIG. 5B, it is also noted that the pusher bar 4110PR is movable independently of the transfer arm LHDA. The pusher bar 4110PR is movably mounted to the frame 4110F in any suitable manner, such as, for example, a guide rod and slide arrangement, and actuated along the Y direction (e.g., a direction generally parallel to the extension / retraction direction of the transfer arm LHDA). In one embodiment, at least one guide rod 4360 is mounted within the loading section 4110PL to guide the movement of the pusher bar 4110PR in the Y direction. In one embodiment, at least a guide rod / slide arrangement is connected within the loading section 4110PL to hold the pusher bar 4110PR. The pusher bar 4110PR is actuated by any suitable motor and transmission, such as a motor 4303 and transmission 4303T. In one embodiment, the motor 4303 is a rotary motor and the transmission 4303T is a belt and pulley transmission. In other embodiments, pusher bar 110PR may be actuated by a linear actuator having substantially no rotating parts.

[0057] The pusher bar 4110PR is positioned within the loading section 4110PL so as to be approximately perpendicular to the rollers 4110RL and not interfere with the pick head 4270 (the pusher bar 4110PR includes slots 4351 through which the fingers 4273A-4273E pass as they lower into the load bed 4110PB, the slots 4351 being sized to allow unhindered movement relative to the fingers 4273A-4273E). The pusher bar 4110PR also includes one or more openings through which the rollers 4110RL pass, the openings being sized to allow free rotation of the rollers about their respective axes. As can be appreciated, the independently operable pusher bar 4110PR does not interfere with the lateral (e.g., Y-direction) extension of the rollers 4110RL, the transfer arm LHDA, and the raising / lowering of the pick head 4270.

[0058] As can be appreciated, lift modules 150A, 150B are under the control of any suitable controller, such as control server 120, such that when picking and placing case units, the pick heads are raised and / or lowered to a predetermined height corresponding to a shelf of an interface station TS at a given storage level 130L. At the interface station TS, pick heads 4000A, 4000B, 4270, or individual portions thereof (e.g., effectors LHDA, LHDB), are extended such that fingers 4273 engage between slats 1210S (shown in FIG. 4B ) below the case unit being picked, corresponding to one or more case unit holding positions at the interface station TS from which one or more case units are picked. The lifts 150A, 150B raise the pick heads 4000A, 4000B, 4270 to lift the case units from the slats 1210S and retract the pick heads 4000A, 4000B, 4270 for transporting the case units to another level of the storage and retrieval system, such as for transporting the case units to the unloading station 160UT. Similarly, to position one or more case units, the pick heads 4000A, 4000B, 4270, or individual parts thereof (e.g., effectors LHDA, LHDB) are extended so that fingers 4273 are above the slats corresponding to one or more case unit holding positions of the interface station TS where the case units or units are positioned. The lifts 150A, 150B lower the pick heads 4000A, 4000B, 4270 to position the case unit on the slats 1210S and so that the fingers 4273 engage between the slats 1210S under the case unit being picked.

[0059] An example of a transport process of case unit(s) by lift 150, including multiple pick and place operations of case unit(s), and on-the-fly sorting of case units to create a mixed pallet load MPL (as shown in FIG. 1C) according to a predetermined order ejection sequence, is described in accordance with aspects of the disclosed embodiment with reference to FIGS. 4A-5B, 9, and 10-10E. In one aspect, the control server 120 commands one or more of the bots 110 to effect classification of case orders of the bots 110's outgoing stream (e.g., processing stream) independent of the order of picking of the cases from the storage area by the bots 110 forming a pick face (as described in the specification of U.S. Provisional Patent Application entitled "Storage retrieval system" and having Attorney Docket No. 1127P015164-US (PAR), filed on January 15, 2016, the entire disclosure of which is already incorporated by reference herein), and commands the lift(s) 150 to effect classification of case orders of the bots 110 (e.g., processing stream) independent of the order of picking of the cases from the storage area by the bots 110 forming a pick face (as described in the specification of U.S. Provisional Patent Application entitled "Storage retrieval system" and having Attorney Docket No. 1127P015164-US (PAR), the entire disclosure of which is already incorporated by reference herein). The bot controller 110C is configured to provide a classification of the outgoing flow of the bot 110 of the case orders (e.g., processing stream) independent of the order in which the case units are placed, for example, at the transfer station(s) TS (or buffer station BS) by the bot 110 (as described in the specification of U.S. Provisional Patent Application entitled "Patent Docket No. 1127P015165-US (PAR)," filed January 15, 2016). In one aspect, the bot controller 110C is configured to provide a classification of the outgoing flow of the bot 110 of the case orders (e.g., processing stream) independent of the order in which the cases are removed from the storage area by the bot 110 that commands the bot 110 and forms the pick face.In yet another aspect, both the control server 120 and the bot controller 110C are configured to effect a classification of the bot 110's outgoing flow of case orders (one or more) that is independent of the order in which the bot 110 commands the bot 110 and forms the pick face to pick up the cases from the storage area. Thus, in one aspect, the control server 120 and / or the bot controller 110C are configured to set the outgoing case flow at least in part by the bot 110's classification of cases that are commonly carried by the bots 110, which is decoupled from the order in which the bot 110 picks up the cases from the storage area. For purposes of explanation, this may be referred to as the bot outgoing flow classification at the transfer station (and / or at the buffer station). In another aspect, control server 120 and / or lift(s) 150 are configured to set outbound case flow, at least in part, by classification by lift 150 of cases commonly carried by lift 150, which is decoupled from the order in which cases are removed from transfer station TS (or buffer station BS) by lift 150. For purposes of explanation, this may be referred to as outbound flow classification by lift at transfer station (and / or at buffer station).

[0060] In one embodiment, multiple transfer decks 130B are provided and arranged on separate levels to define a multi-level deck in the manner described above (FIG. 9B, block 900). One or more bots 110 are disposed on each of the multiple levels of transfer decks 130B to hold and transport pick faces on each transfer deck 130B as described above (FIG. 9B, block 910). Pick faces are raised and / or lowered from the multi-level decks 130B according to a load unloading sequence using at least one outgoing lift 150B that traverses and connects two or more levels of the multi-level decks 130B in a manner substantially similar to that described below (FIG. 9B, block 920). As can be appreciated, each load shipment (such as a truck load filled with cases from the storage and retrieval system 100, a pallet load, etc.) from the distribution center or warehouse in which the storage and retrieval system 100 is located has a predetermined sequence or order of case loads (single case or mixed cases) that the case loads are combined to fill the load shipment (e.g., a load shipment order sequence determined in any suitable manner such as described in U.S. patent application Ser. No. 13 / 654,293, filed Oct. 17, 2012, the entire disclosure of which has already been incorporated by reference herein), and / or a rules-based system based on customer criteria, loading / unloading criteria, or any other suitable criteria. As described below, transfer of pick faces (e.g., case units) between the bot 110 and at least one outgoing lift 150B is effected using at least one transfer station TS (or buffer station BS) on each transfer deck 130B that provides interaction between the bot 110 on the respective transfer deck 130B and the at least one outgoing lift 150B (FIG. 9B, block 930).In one embodiment, each outgoing lift 150B defines at least one case load stream of an order processing stream including mixed case pick faces that are outgoing from the multi-level deck 130B to the load outgoing fill or load fill, and at least one case load stream of the processing stream is arranged in an order sequence of streaming pick faces related to a predetermined sequence of outgoing load fills (e.g., individual case load streams of lifts 150B form order processing streams corresponding to the outgoing load fills) (FIG. 9B, block 940). As can be appreciated, at least one transfer station TS (or buffer station BS) on at least one of the multi-level decks commonly supports two or more of the mixed case pick faces (e.g., defining a portion of the streaming pick faces in the order sequence of streaming pick faces) based on, for example, a predetermined sequence of outgoing load fills. In one embodiment, the interface station TS (or buffer station BS) forms a common pick face transfer interface for at least one outgoing lift 150B such that the commonly supported pick faces are commonly retrieved using at least one outgoing lift 150B. In one embodiment, the interface station TS (or buffer station BS) commonly supports two or more of the mixed case pick faces in an order sequence based on a predetermined sequence of outgoing load fillings. As can be understood, any suitable control device, such as the control server 120, is configured to communicate with one or more bots 110 and effect placement of the pick faces on at least one transfer station TS (or buffer station BS) based on the order sequence of the streaming pick faces. In one embodiment, the order sequence of the streaming pick faces is based on, for example, another processing stream of another outgoing lift 150B.As can be appreciated, when there are two or more case load streams (e.g., from multiple outgoing lifts 150B), the case loads of each case load stream are associated with a predetermined sequence of outgoing load fills and with each other in a corresponding order sequence to provide coordinated and harmonious integration of the case loads within each stream in the outgoing load fill (e.g., the individual case load streams are combined according to a predetermined sequence of outgoing load fills to form an order processing stream in which a first order sequence of streaming pick faces from a first lift complements a second order sequence of streaming pick faces from a second lift) (Figure 9B, block 950). In one aspect, the order sequence of case loads in each case load stream is defined by the order sequence of multiple case loads on each outgoing (e.g., outbound) stroke of the outgoing lift 150B that generates / supplies the case load stream of multiple case loads (see, e.g., FIG. 1E where sequencing 174 is performed by the vertical case transport 173 of the outgoing lift 150B).

[0061] 9, there are two output lifts 150B1, 150B2, each having a respective case load stream COS1, COS2 that is transported through a transfer station 160TS, 160TSA to an output conveyor 160CB (in other embodiments, any suitable number of output lifts are present with any suitable number of corresponding case load streams provided to the output load filling). For example, the order sequence of the case loads in each case load stream COS1, COS2 is defined by the order sequence of the multiple case loads of each load output (outgoing) stroke of the respective lift 150B1, 150B2 that generates / supplies the case load stream COS1, COS2 (e.g., the multiple loads of each lift load output stroke are arranged in an order sequence relative to the filling sequence). Here, the order processing stream is defined by the two lifts 150B1, 150B2, although in other embodiments, the order processing stream is defined by one of the lifts 150B1, 150B2 independent of the other of the lifts 150B1, 150B2.

[0062] In one embodiment, sorting of multiple loads to order / fill sequence occurs both prior to and / or during lift pick. For example, sorting prior to lift pick includes sending case units / pick faces (e.g., multiple case loads) by the bot 110 to interface station shelves 7000A-7000L of transfer station TS at another transfer deck level 130B. In one embodiment, the timing of case load delivery by the bot 110 to transfer station TS is out of sequence, but the delivered case loads correspond to a predetermined sequence of case load streams COS1, COS2 delivered by the respective outbound lifts 150B1, 150B2 to effect the order fill sequence. For example, the multi-case loads are placed on interface stations TS (at one or more deck levels) in a sorted arrangement (even if not sequenced in terms of timing of delivery) to fulfill the order sequence (e.g., at least the case units required for the order sequence are placed on the interface stations TS in a known relationship to their respective interface stations TS) for each load unloading and filling sequence. As described below, in one embodiment, lift 150 removes multi-case loads from interface stations TS located at one or more deck levels to supply respective case load streams COS1, COS2. In one embodiment, the load discharge filling sequence of each lift 150B is a continuous sequence (n) (e.g., when a single stream COS1, COS2 forms the output load fill) or a continuous skip sequence (n+i, i=1 to m, where i corresponds to the number of load streams COS1, COS2 combined into the output load fill) where there are multiple streams COS1, COS2 forming the output load fill in a continuous skip sequence.In the latter case, the order sequence of each lift interface station TS (or buffer station BS) is matched or related to the order sequences of the other load streams that merge into the outgoing load fill.

[0063] As an example, FIG. 9 illustrates an outgoing load packing in which two case load streams COS1, COS2 are combined to form an outgoing load packing for a customer order, where at least one of the case load streams COS1, COS2 is associated with a predetermined pick face load order sequence for the outgoing load packing. For illustrative purposes, the customer order may require case unit(s) 1-8 to be served by two lifts 150B1, 150B2. Here, case units 1 and 3 are removed by lift 150B1 into case load stream COS1, while case units 2 and 4 are removed into case load stream COS2 such that the cases arrive at the outgoing station 160US in an alternative manner defined by the order sequence of the processing streams. From separate holding positions on one or more interface station shelves 7000A-7000F, case loads 7 and 5 are delivered to the output conveyor 160CB according to an order sequence such that the case units are carried and transferred in one pass through the stack of the interface station TS by a common load handling device LHD of the lift 150B1. To efficiently use each lift 150 in the storage and retrieval system 100, a controller such as the control server 120 determines which interface station(s) the case units 5, 7 are located on. The controller sends commands to a lift such as the lift 150B1 associated with the interface station TS at which the case units 5, 7 are located to retrieve one or more of the outgoing case units. As described herein, in one embodiment, the lift 150 may move cases from the interface stations TS at separate storage levels to the interface stations of the outgoing conveyor.In other aspects, the lift 150 may move case units between storage levels, such as from shelf 7000A to shelf 7000D, and case units transferred from shelf 7000A may be removed by the lift 150 from shelf 7000D (e.g., combined with case units pre-positioned on shelf 7000D) for transport to an interface station of an outbound conveyor. In one aspect, the control server 120 is configured to provide a classification of the outbound flow of the lift 150 of the case order(s) (which may also be referred to as order processing, processing stream(s), or outbound stream(s)) independent of the order of picking of the cases from the storage area by the bots 110 that command the lift 150 and form the pick faces. For purposes of explanation, this may be referred to as outbound flow classification by the lift 150 at the transfer station (and / or buffer station).

[0064] For example, referring to FIG. 9, a customer order may call for case units 7 and 5 to be delivered from separate holding locations on one or more interface station shelves 7000A-7000F to an output conveyor 160CB for transport and transfer by a common load handling device LHD of lift 150B1 in a single pass through the stack at interface station TS. To efficiently use each lift 150 in storage and retrieval system 100, a controller, such as control server 120, determines which interface station(s) case units 5, 7 are located on. The controller sends commands to a lift, such as lift 150B1 associated with the interface station TS at which case units 5, 7 are located, to retrieve one or more of the outgoing case units.

[0065] In one aspect in which the lift 150B1 removes case units 5, 7 from the common shelf 7000B of the interface station TS, the lift 150B1 moves one or more of the lift's load handling devices LHD, LHD1, LHD2 (and the removal heads 4000A, 4000B, 4000C, 4000D, 4270 thereon) in the Z direction so that the transfer arms LHDA, LHDB are positioned substantially at the level of the interface station shelf 7000B (Figure 10F, block 11000). The transfer arms LHDA, LHDB of the one or more load handling devices LHD, LHD1, LHD2 are extended in the Y direction (e.g., extension of a common transfer arm as in FIG. 4A, or extension of two transfer arms substantially simultaneously as in FIGS. 5 and 5A) such that the fingers 4273 are positioned between the slats 1210S below the case units 5, 7 (FIG. 10F, block 11010). The lift 150B1 moves the one or more load handling devices LHD, LHD1, LHD2 in the Z direction (FIG. 10F, block 11020) such that the fingers 4273 pass between the slats 1210S to lift / remove the case units 5, 7 from the interface station shelf 7000B. The transfer arms LHDA, LHDB are retracted in the Y direction to position the case units 5, 7 within the transfer column TC of the lift 150B1 (e.g., the area of ​​open space where the load handling devices move along the Z direction without interference from the interface stations and outgoing conveyors) (FIG. 10F, block 11030). The lift 150B1 moves the one or more load handling devices LHD, LHD1, LHD2 in the Z direction so that the transfer arms LHDA, LHDB are located substantially at the level of the interface station 160TS of the conveyor 160CB (FIG. 10F, block 11040).The transfer arms LHDA, LHDB of the one or more load handling devices LHD, LHD1, LHD2 are extended in the Y direction to position the case units 5, 7 substantially above the interface station 160TS (FIG. 10F, block 11050), and the lift 150B1 moves the one or more load handling devices LHD, LHD1, LHD2 in the Z direction so that the fingers 4273 pass between the slats of the interface station 160TS (in a manner similar to that shown in FIG. 4B) to lower / position the case units 5, 7 on the shelves of the interface station 160TS (FIG. 10F, block 11060). The transfer arms LHDA, LHDB are retracted in the Y direction to position the transfer arms LHDA, LHDB in the transfer column TC of the lift 150B1 (FIG. 10F, block 11070). Here, case units carried at all load stations LST1-LST3 (e.g., case unit holding positions) of the common platform PFM (e.g., as in FIG. 4A and FIG. 5, 5A where simultaneous extension / retraction of transfer arms LHDA, LHDB results in a common platform) are picked, transferred, and placed in unison with the lift platform on the common elevator. In one embodiment according to the above case load streams COS1, COS2, case units 6, 8 are transferred by lift 150B1 to outgoing conveyor 160CB in a manner substantially similar to that described above with respect to the transfer of case units 5, 7 by lift 150B1. As can be appreciated, the load fill formed by case load streams COS1, COS2 includes mixed case pick faces arranged in a predetermined pick face load order sequence. In one embodiment, streaming pick faces 1, 3, 5, 7 (e.g., case load stream COS1) are combined with pick faces 2, 4, 6, 8 from other case load stream COS2 to fill load fills in a given pick face load order sequence 1, 2, 3, 4, 5, 6, 7, 8.In one embodiment, at least one pick face from another case load stream COS2 is combined with an order sequence of streaming pick faces from case load stream COS1 to form part of the consecutively ordered pick faces (e.g., pick faces 1, 2, 3, 4, ... shown in Figure 9) of a given pick face load order sequence.

[0066] In one embodiment, as described above, when lift 150 removes multi-load cases from interface stations TS located as separate deck levels, it sorts the multi-load cases if the sorting sequence corresponds to the order sequence of the streaming pick face (e.g., case load streams COS1, COS2). In one embodiment, a multiple transfer arm load handling device LHD as in FIG. 5 (and the individually operable load handling devices LHD1, LHD2 in FIG. 5A) removes and places case units from two or more interface stations TS located at separate storage levels 130LA, 130LB and transfers the case units to the same or another outgoing conveyor transfer station TS (e.g., when one or more outgoing conveyor transfer stations TS handling a common lift 150 are stacked one on top of the other). For illustrative purposes only, a customer order may call for case units 7, 9 to be sent to conveyor 160CB. To efficiently use each lift 150 in storage and retrieval system 100, a controller, such as control server 120, determines which interface station(s) case units 7, 9 are located on. The controller sends commands to a lift, such as lift 150B1 associated with the interface station TS at which case units 7, 9 are located, to retrieve one or more of the outgoing case units in a single pass of the load handling device LHD. Here, the case units 7, 9 are positioned on different shelves 7000A-7000F of different interface stations TS such that the lift 150B1 moves one or more of the lift's load handling devices LHD, LHD1, LHD2 (and the removal heads 4000A, 4000B, 4000C, 4000D, 4270 thereon) in the Z direction, whereby the transfer arms LHDA, LHDB are substantially positioned on levels 130LA, 130LC of one of the interface station shelves 7000A, 7000B (Figure 10G, block 12000).The transfer arm LHDA, LHDB of the one or more load handling devices LHD, LHD1, LHD2 is extended in the Y direction such that the finger 4273 is positioned between the slats 1210S below one of the case units 7, 9, such as case unit 7 if case unit 7 is to be removed on an upward stroke of the lift 150B before removing case unit 9, or case unit 9 if case unit 9 is to be removed on a downward stroke of the lift 150B before removing case unit 7 (FIG. 10G, block 12010). The lift 150B1 moves the one or more load handling devices LHD, LHD1, LHD2 of the lift in the Z direction such that the finger 4273 passes between the slats 1210S to lift / remove one of the case units 7, 9 (which in some embodiments may be a pick face including two or more case units) (FIG. 10G, block 12020). The transfer arms LHDA, LHDB are retracted in the Y direction to position the case units 7, 9 within the transfer column TC of the lift 150B1 (e.g., an area of ​​open space where the load handling devices move along the Z direction without interference from the interface station and the outgoing conveyor) (FIG. 10G, block 12030). The lift 150B1 moves one or more load handling devices LHD, LHD1, LHD2 in the Z direction so that the transfer arms LHDA, LHDB are positioned substantially at the level of the interface station shelves 7000A, 7000B where the other case units 7, 9 are located (FIG. 10G, block 12035) to retrieve other case units in the manner described above (FIG. 10G, blocks 12010, 12020, 12030). The lift 150B1 moves one or more load handling devices LHD, LHD1, LHD2 in the Z direction so that the transfer arms LHDA, LHDB are positioned substantially at the level of the interface station 160TS of the conveyor 160CB (FIG. 10G, block 12035).The transfer arms LHDA, LHDB of one or more load handling devices LHD, LHD1, LHD2 are extended in the Y direction to position the case units 7, 9 substantially above the interface station 160TS (FIG. 10G, block 12050), and the lift 150B1 moves the one or more load handling devices LHD, LHD1, LHD2 in the Z direction so that the fingers 4273 pass between the slats of the interface station 160TS (in a manner similar to that shown in FIG. 4B) to lower / position the case units 7, 9 on the shelves of the interface station 160TS (FIG. 10G, block 12060). In one embodiment, the case units 7, 9 are placed on the interface station 160TS as one unit at substantially the same time, while in other embodiments, the case units 7, 9 are placed on the interface station 160TS sequentially at different times, such as one by one (e.g., when the transfer stations TS of one or more outgoing conveyors handling a common lift 150 are stacked on top of one another) and placed at separate outgoing conveyor interface stations 160TS according to a predetermined order ejection sequence to build a mixed pallet MPL (FIG. 1C). The transfer arms LHDA, LHDB are retracted in the Y direction to position the transfer arms LHDA, LHDB in the transfer column TC of the lift 150B1 (FIG. 10G, block 12070).

[0067] In one embodiment, the common load handling device LHD, LHD1, LHD2 is configured to retrieve / place one or more case units from the multiple interface station TS shelves using a common transfer arm, and the case units are sorted and / or aligned on the fly (e.g., during transport on the lift) on the load handling device LHD, LHD1, LHD2. For example, the outgoing case units 5, 7 are located on the interface station shelves 7000B, 7000B of the separate storage levels 130LA, 130LB. Also, to efficiently use each lift 150 in the storage and retrieval system 100, a controller such as the control server 120 determines which interface station(s) the case units 5, 7 are located on. The controller sends commands to a lift, such as lift 150B1 associated with the interface station TS where the case units 5, 7 are located, to retrieve one or more of the outgoing case units in one pass of the load handling device LHD. Now, for example, referring to Figures 9, 10 and 10A-10E, the load handling devices LHD, LHD1, LHD2 of the lift 150B remove a case unit 7 (which may be the pick face of two or more case units) from the interface station shelf 7000B in the manner described above. The case unit(s) 7 are aligned on the load handling devices toward the rear of the loading section 4110PL (Figure 10H, block 13000), as described in more detail below. The load handling devices LHD, LHD1, LHD2 continue to move along the mast 4002 in a common path of the vertical stack of the interface station TS, and remove a case unit 5 from a different interface station shelf 7000D using the common transfer arm LHDA, such that both case units 7, 5 are positioned next to each other on the common transfer arm LHDA (Figure 10H, block 13010).As can be appreciated, in one aspect, the control device 120 is configured to effect removal of the case unit(s) 5, 7 in any suitable order, such as, for example, an order opposite to the order in which the case unit(s) are placed at the interface station 160TS of the conveyor 160CB in accordance with a predetermined order ejection sequence to form a mixed pallet MPL.

[0068] Here, the load handling devices LHD, LHD1, LHD2 grip both case units 7, 5 in the loading section 4110PL in a manner described below (FIG. 10H, block 13020). The load handling devices LHD, LHD1, LHD2 separate the case units 7, 5 in the loading section 4110PL such that the case unit(s) are separated in any suitable manner, such as, for example, the case unit(s) 5 are aligned toward the front of the loading section 4110PL and the case unit(s) 7 are aligned toward the rear of the loading section 4110PL, as described in more detail below (FIG. 10H, block 13040). At least the case unit 5 is transferred to the interface station 160TS (FIG. 10H, block 13050). The load handling devices LHAD, LHD1, LHD2 retract the transfer arms LHDA, LHDB and grip the case unit 7 (FIG. 10H, block 13020) to return the case unit(s) 7 that are not to be transferred (e.g., case units that are kept in the loading section) to the loading section 4110PL (FIG. 10H, block 13060). The case unit(s) 7 are transported to another interface station 160TSA of the output lift 150B1 (or sequentially placed at the same interface station 160TS after placement of the case unit(s) 5 at the interface station 160TS) (FIG. 10H, block 13030), aligned toward the front of the loading section 4110PL (FIG. 10H, block 13040), and transferred to the interface stations 160TS, 160TSA as described above (FIG. 10H, block 13050). In another aspect, depending on a predetermined case unit unloading sequence, the load handling devices LHD, LHD1, LHD2 simultaneously position both case units 7, 5 at a common location / position, e.g., a single interface station of lift 150B1.

[0069] 6, as described above, the bot 110 includes a transfer arm 110PA that effects the picking and placing of case units from the stacked storage spaces 130S (defined at least in part in the Z direction), interface stations TS and peripheral buffer stations BS, BSD (e.g., the storage spaces, interface stations and / or peripheral buffer stations may be further defined in the X and Y directions through dynamic allocation of case units as described above) by one or more of the rails 1210A-1210C, 1200. The bot 110 transports case units between each lift module 150 on each storage level 130L and each storage space 130S as described above. The bot 110 includes a frame 110F having a drive section 110DR and a loading section 110PL. The drive section 110DR includes one or more drive wheel motors, each connected to a respective drive wheel 202. In this embodiment, the bot 110 includes two drive wheels 202 disposed on either side of the bot 110 at the end 110E1 (e.g., the first longitudinal end) of the bot 110 to support the bot 110 on a suitable drive surface, although in other embodiments, any suitable number of drive wheels are provided on the bot 110. In one embodiment, each drive wheel 202 is independently controlled such that the bot 110 can be steered through differential rotation of the drive wheels 202, although in other embodiments, the rotation of the drive wheels 202 may be coupled to rotate at substantially the same speed. Any suitable wheels 201 are attached to the frame on either side of the bot 110 at the end 110E2 (e.g., the second longitudinal end) of the bot 110 to support the bot 110 on a drive surface. In one embodiment, the wheels 201 are freely rotating caster wheels, which allow the bot 110 to pivot through differential rotation of the drive wheels 202 to change the direction of travel of the bot 110.In other embodiments, the wheels 201 are steerable wheels that, for example, turn under the control of the bot controller 110C (configured to provide control of the bot 110 as described herein) to change the direction of movement of the bot 110. In one embodiment, the bot 110 includes one or more guide wheels 110GW, for example, at one or more corners of the frame 110F. The guide wheels 110GW may interact with the storage structure 130, such as guide rails (not shown) in the retrieval aisle 130A on the transfer deck 130B and / or at an interface or transfer station, to interact with the lift module 150 to guide and / or position the bot 110 a predetermined distance to where one or more case units are to be placed and / or from where one or more case units are to be retrieved, as described, for example, in U.S. patent application Ser. No. 13 / 326,423, filed Dec. 15, 2011, the disclosure of which is incorporated herein by reference in its entirety. As described above, the bot 110 may enter the retrieval corridor 130A having different opposing directions to access the storage spaces 130S disposed on either side of the retrieval corridor 130A. For example, the bot 110 may enter the retrieval corridor 130A with the end 110E2 leading the direction of movement, or the bot 110 may enter the retrieval corridor 130A with the end 110E1 leading the direction of movement.

[0070] The loading section 110PL of the bot 110 includes a loading bed 110PB, a fence or reference member 110PF, a transfer arm 110PA, and a pusher bar or member 110PR. In one embodiment, the loading bed 110PB includes one or more rollers 110RL that are laterally attached to the frame 110F (e.g., relative to the longitudinal axis LX of the bot 110) so that one or more case units carried in the loading section 110PL can be moved longitudinally along the longitudinal axis of the bot (e.g., to justify with respect to a predetermined position of the frame / loading section and / or with respect to one or more case unit position references), for example, to position the case unit in a predetermined position in the loading section 110PL and / or with respect to other case units in the loading section 110PL (e.g., longitudinal forward / rearward alignment of the case unit). In one embodiment, the rollers 110RL may be driven (e.g., rotated about their respective axes) by any suitable motor to move the case units within the loading section 110PL. In another embodiment, the bot 110 includes one or more longitudinally movable pusher bars (not shown) that push the case units past the rollers 110RL to move the case units to a predetermined position within the loading section 110PL. The longitudinally movable pusher bars may be substantially similar to those described, for example, in U.S. Patent Application No. 13 / 326,952, filed December 15, 2011, the entire disclosure of which has been previously incorporated by reference herein. The pusher bar 110PR is movable in the Y direction relative to the reference coordinate system REF of the bot 110 to provide lateral alignment of the case units within the loading area 110PL along the fence 110PF and / or the pick-up head 270 of the transfer arm 110PA in a manner described in U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, the entire disclosure of which is already incorporated by reference herein.

[0071] Still referring to FIG. 6, the case units are placed on and removed from the load bed 110PB by the transfer arm 110PA. The transfer arm 110PA includes a lift mechanism or unit 200 located substantially within the load section 110PL, as described, for example, in U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, the entire disclosure of which has already been incorporated by reference herein. The lift mechanism 200 provides both coarse and fine positioning of the pick faces gripped by the bot 110, which are lifted to a location in the storage structure 130 for retrieval and / or placement of the pick faces and / or individual case units into the storage space 130S (e.g., on the respective storage level 130L where the bot 110 is located). For example, the lift mechanism 200 provides for the removal and placement of case units at multiple elevated storage shelf levels 130LS1-130LS4, TL1, TL2 accessible from a common removal aisle or interface station deck 1200S (see, e.g., Figures 1A, 2B and 3B).

[0072] The lift mechanism 200 is configured to perform combined robot axis movements (e.g., combined substantially simultaneous movements of the pusher bar 110PR, the lift mechanism 200, the pick head extensions, and the front / rear alignment mechanism, such as the longitudinally movable pusher bar described above) so that different / multiple SKUs or multiple pick loads can be handled by the bot. In one embodiment, the operation of the lift mechanism 200 is independent of the operation of the pusher bar 110PR, as described below. Decoupling the axes of the lift mechanism 200 and the pusher bar 110PR results in combined pick / place sequences, which can result in reduced pick / place cycle times, increased throughput of the storage and pick system, and / or increased storage density of the storage and pick system, as described above. For example, the lift mechanism 200 can provide picking and placing of case units at multiple elevated storage shelf levels accessible from a common pick aisle and / or interface station deck 1200S, as described above.

[0073] The lift mechanism may be configured in any suitable manner to move the pick head 270 of the bot 110 bidirectionally along the Z axis (e.g., reciprocating in the Z direction, see FIG. 6). In one embodiment, the lift mechanism includes a mast 200M, and the pick head 270 is movably mounted to the mast 200M in any suitable manner. The mast is movably mounted to the frame in any suitable manner to be movable along the lateral axis LT of the bot 110 (e.g., in the Y direction). In one embodiment, the frame includes guide rails 210A, 210B to which the mast 200 is slidably mounted. The transfer arm drives 250A, 250B may be mounted to the frame to effect movement of the transfer arm 110PA along at least the lateral axis LT (e.g., the Y axis) and the Z axis. In one embodiment, the transfer arm drives 250A, 250B include an extension motor 301 and a lift motor 302. The extension motor 301 may be mounted on the frame 110F and may be coupled to the mast 200M in any suitable manner, such as a belt and pulley transmission 260A, a screw drive transmission (not shown) and / or a gear drive transmission (not shown). The lift motor 302 may be mounted on the mast 200M and may be coupled to the pick-up head 270 in any suitable manner, such as a belt and pulley transmission 271, a screw drive transmission (not shown) and / or a gear drive transmission (not shown). As an example, the mast 200M includes guides, such as guide rails 280A, 280B, and the pick-up head 270 is mounted along the guide rails 280A, 280B for guided movement in the Z direction along the guide rails 280A, 280B. In other embodiments, the pick-up head is mounted to the mast in any suitable manner for guided movement in the Z direction. With respect to the transmission unit 271, the belt 271B of the belt and pulley transmission unit 271 is fixedly connected to the removal head 270 so that when the belt 271 moves (e.g., driven by the motor 302), the removal head 270 moves together with the belt 271 and is driven in both directions in the Z direction along the guide rails 280A, 280B.As can be appreciated, if a screw drive is used to drive the pick head 270 in the Z direction, a nut may be attached to the pick head 270 such that engagement between the nut and the screw causes movement of the pick head 270 when the screw is redirected by the motor 302. Similarly, if a gear drive transmission is used, a rack and pinion or any other suitable gear drive may drive the pick head 270 in the Z direction. In other embodiments, any suitable linear actuator is used to move the pick head in the Z direction. The transmission 260A for the extension motor 301 is substantially similar to that described herein with respect to the transmission 271.

[0074] Still referring to FIG. 6, the pick head 270 of the bot 110 transfers case units between the bot 110 and a case unit pick / placement location, such as, for example, the storage space 130S, the peripheral buffer stations BS, BSD, and / or the interface station TS (see FIGS. 2A-3B), or in other embodiments, directly between the bot 110 and the lift module 150. In one embodiment, the pick head 270 includes a base member 272, one or more tines or fingers 273A-273E, and one or more actuators 274A, 274B. The base member 272 is attached to the mast 200M as described above to ride along the guide rails 280A, 280B. One or more tines 273A-273E are attached to base member 272 at their proximal ends such that distal (e.g., free) ends of tines 273A-273E are cantilevered from base member 272. Referring again to FIG. 1B, tines 273A-273E are configured for insertion between slats 1210S that form case unit support surfaces CUSP of the storage shelf.

[0075] One or more of the tines 273A-273E are movably mounted to the base member 272 (such as on slide / guide rails similar to those described above) such that they are movable in the Z direction. In other embodiments, any number of tines may be mounted to the base member 272, but in the embodiment shown in the drawings, for example, five tines 273A-273E are mounted to the base member 272. While any number of the tines 273A-273E may be movably mounted to the base member 272, in the embodiment shown in the drawings, for example, the outermost tines 273A, 273E (with respect to the centerline CL of the pick head 270) are movably mounted to the base member 272, while the remaining tines 273B-273D are immovable relative to the base member 272.

[0076] In this embodiment, the pick head 270 uses only three tines 273B-273D to transfer smaller sized case units (and / or groups of case units) to and from the bot 110, and five tines 273A-273E to transfer larger sized case units (and / or groups of case units) to and from the bot 110. In other embodiments, fewer than three tines are used to transfer smaller sized case units (e.g., when three or more tines are movably attached to the base member 272). For example, in one embodiment, all but one of the tines 273A-273E are movably attached to the base member such that the smallest case unit being transferred to and from the bot 110 has a width as large as the distance X1 between the slats 1210S, e.g., without interfering with other case units on the storage shelf (see FIG. 1B).

[0077] The non-movable tines 373B-373D define the pick surface SP of the pick head 270 and are used when transporting case units (and / or pick faces) of all sizes, while the movable tines 373A, 373E are selectively raised and lowered (e.g., in the Z direction by actuators 274A, 274B) relative to the non-movable tines 373B-373D to transport larger case units (and / or pick faces). Still referring to FIG. 6, an example is shown in which all of the tines 373A-373E are positioned such that the case unit support surface SF of each tine 273A-273E coincides with the pick-up surface SP of the pick-up head 270, however, as can be appreciated, the case unit support surfaces SF of the tines 273A, 273E are offset (e.g., downward) from the pick-up surface SP, and the two end tines 273A, 273E are movable to be positioned lower (e.g., in the Z direction) relative to the other tines 273B-273D so that the tines 273A, 273E do not contact one or more case units gripped by the pick-up head 270 and do not interfere with unpicked case units positioned in the storage space 130S or any other suitable case unit holding position on the storage shelf.

[0078] Movement of the tines 273A-273E in the Z direction is effected by one or more actuators 274A, 274B mounted to the transfer arm 110PA at any suitable location. In one embodiment, the one or more actuators 274A, 274B are mounted to the base member 272 of the pick head 270. The one or more actuators are any suitable actuators, such as linear actuators, capable of moving one or more tines 273A-273E in the Z direction. For example, in the embodiment shown in FIG. 6, there is one actuator 274A, 274B for each of the moveable tines 273A, 273E such that each moveable tine is independently moveable in the Z direction. In other embodiments, one actuator may be coupled to two or more moveable tines such that the two or more moveable tines move as a unit in the Z direction.

[0079] As can be appreciated, movably mounting one or more tines 273A-273E on the base member 272 of the pick head 270 provides full support for larger case units and / or pick faces on the pick head 270 while also providing the ability to pick and place smaller case units without interfering with other case units located on, for example, the storage shelves, interface stations and / or peripheral buffer stations. The ability to pick and place case units of various sizes without interfering with other case units on the storage shelves, interface stations and / or peripheral buffer stations reduces the size of the gaps GP (see FIG. 1A) between case units on the storage shelves. As can be appreciated, because the tines 273B-273D are fixed to the base member 272, the raising and lowering of the case units and / or pick faces to and from the case unit holding positions is effected solely by the lift motors 301, 301A, so there is no overlapping motion when picking / placing case units.

[0080] Referring again to FIG. 6, it is also noted that the pusher bar 110PR is movable independently of the transfer arm 110PA. The pusher bar 110PR is movably mounted to the frame in any suitable manner, such as, for example, a guide rod and slide arrangement, and is actuated along the Y direction (e.g., a direction generally parallel to the extension / retraction direction of the transfer arm 110PA). In one embodiment, at least one guide rod 360 is mounted within the loading section 110PL to extend transversely to the longitudinal axis LX of the frame 110F. The pusher bar 110PR may include at least one slide member 360S configured to engage and slide along a respective guide rod 360. In one embodiment, at least the guide rod / slide arrangement is coupled within the loading section 110PL to hold the pusher bar 110PR. The pusher bar 110PR is actuated by any suitable motor and transmission, such as a motor 303 and transmission 303T. In one embodiment, motor 303 is a rotary motor and transmission 303T is a belt and pulley transmission. In other embodiments, pusher bar 110PR may be actuated by a linear actuator having substantially no rotating parts.

[0081] The pusher bar 110PR is disposed in the loading section 110PL so as to be substantially perpendicular to the rollers 110RL and not to interfere with the pick-up head 270. As can be seen in FIG. 10B, the bot 110 is in a transport configuration in which at least one case unit is supported on the rollers 110RL (e.g., the rollers collectively form a loading bed). In the transport configuration, the tines 273A-273E of the pick-up head 270 are intermeshed with the rollers 110RL and disposed below (along the Z direction) the case unit support surface RSP (see FIG. 10) of the rollers 110RL. The pusher bar 110PR is configured with grooves 351 (FIG. 10C) in which the tines 273A-273E are received, with sufficient clearance in the grooves 351 to allow the tines to move below the case unit support surface RSP and to allow free movement of the pusher bar 110PR without interference from the tines 273A-273E. The pusher bar 110PR also includes one or more openings through which the rollers 110RL pass, the openings being sized to allow free rotation of the rollers about their respective axes. As can be appreciated, the independently operable pusher bar 110PR does not interfere with the lateral (e.g., Y-direction) extension of the rollers 110RL, the transfer arm 110PA, and the raising / lowering of the pick head 270.

[0082] As described above, with respect to both the bot 110 and the load handling devices LHD, LHD1, LHD2, the pusher bar 110PR is a separate and independent axis of the bot 110 and / or the load handling devices LHD, LHD1, LHD2 that operates without interference from the extension and lift axes of the removal heads 270, 4270, so that the pusher bar 110PR, 4110PR can be operated substantially simultaneously with the lifting and / or extension of the transfer arms 110PA, LHDA, LHDB. Combined axial movement (e.g., simultaneous movement of the pusher bars 110PR, 4110PR with the extension and / or lift axes of the transfer arms 110PA, LHDA, LHDB) results in increased loading operation throughput and provides ordered multiple removal (e.g., by a predetermined load removal sequence) of two or more case units from a common removal aisle or from shelves 7000A-7000F of one or more interface stations, in one common path of the removal aisle or vertical stack of the interface station TS. For example, referring to Figures 10-10A, during a multiple pick / place sequence of the transfer arm 110PA, LHDA, LHDB, the pusher bar 110PR, 4110PR is pre-positioned (when the case unit and / or pick face is picked and transferred into the loading section 110PL, 4110PL) a predetermined distance X2 (note that the distances / depths X2, X3, X4 are shown here with respect to the load handling device of Figures 10-10E, but the distances, depths X2, X3, X4 apply equally to the bot 110) away from the contact depth X3 (e.g., the depth of the tines occupied by the case unit and / or pick face CU, 7 when it is picked / placed from the storage space, shelf 7000D of the interface station or other case unit holding position) (Figure 14, block 1100). Distance X2 is the minimum distance that provides sufficient clearance between pusher bar 110PR and the case unit to allow the case unit to seat on rollers 110RL, 4110RL.When the case unit CU, 7 is lowered onto the rollers 110RL, 4110RL (Figure 14, block 1110), the distance travelled by the pusher bar 110PR, 4110PR to contact the case unit CU, 7 is a shorter distance X2 compared to the distance X4 travelled by a conventional transport vehicle when moving from the rear 402, 4402 of the loading section 110PL, 4110PL (relative to the lateral Y direction and access side 401, 4401 of the loading section 110PL, 4110PL). When the case unit CU,7 is lowered by the transfer arm 110PA, LHDA, LHDB and transferred to the rollers 110RL, 4110RL so as to be supported only by the rollers 110RL, 4110RL, the pusher bar 110PR, 4110PR is actuated forward (relative to the lateral and access sides 401, 4401 of the loading section 110PL, 4110PL) to align the case unit CU,7 (FIG. 14, block 1120). For example, the pusher bar 110PB, 4110PB may push the case unit CU,7 laterally in the Y direction so that the case unit contacts the fence 110PF, 4110PF (located on the access side 401, 4401 of the loading section 110PL, 4110PL so that the reference position of the case unit can be formed through the contact between the case unit CU,7 and the fence 110PF, 4110PF). In one embodiment, the pusher bar 110PR, 4110PR may engage or grip the case unit CU, 7 during transport of the case unit (e.g., to hold the case unit against the fence 110PF, 4110PF) to maintain the case unit CU, 7 in a predetermined spatial relationship relative to each other and to one of the reference frames REF or REFL (FIGS. 5B and 6) of the bot 110 and the load handling device LHD, LHD1, LHD2, respectively. (FIG. 14, block 1130) When the case unit is positioned, the pusher bar 110PR, 4110PR is withdrawn from contact with the case unit CU, 7 (e.g., in the Y direction) after aligning the case unit CU, 7 with the fence 110PF, 4110PF (FIG. 14, block 1140).Substantially immediately after the pusher bar 110PR, 4110PR disengages from the case unit CU, 7, one or more of the lift axis (e.g., in the Z direction) and extension axis (e.g., in the Y direction) of the transfer arm 110PA, 4110PA are actuated ( FIG. 14 , block 1150) substantially simultaneously with the withdrawal movement of the pusher bar 110PR, 4110PR. In one embodiment, both the lift axis and the extension axis are actuated as the pusher bar is withdrawn from contact with the case unit CU, 7, while in other embodiments, only one of the lift axis and the extension axis is actuated. As can be appreciated, the simultaneous operation of the lifting and / or extension axes of the transfer arms 110PA, 4110PA with the retraction of the pusher bars 110PR, 4110PR, and the reduction in the distance the pushers travel to align the case units CU, 7, reduces the time required to transfer case units CU, 7 (e.g., stored / sorted in the load handling devices LHD, LHD1, LHD2 or the bot 110) to and from the bot 110 or load handling devices LHD, LHD1, LHD2, and increases the throughput of the storage and retrieval system 100.

[0083] As described herein, with reference to FIGS. 2A, 2B, and 12, the bot 110 is configured to transport pick faces between the pick-up aisle 130A and the transfer / handover station TS and the buffer station BS. In one embodiment, the control server 120 is configured to instruct the bot 110 to cause the bot 110 to classify the order of cases of the outgoing flow independent of the order of cases taken from the storage area by the bot 110 forming the pick face. In one embodiment, the bot control device 110C is configured to instruct the bot 110 to cause the bot 110 to classify the order of cases of the outgoing flow independent of the order of cases taken from the storage area by the bot 110 forming the pick face. In yet another embodiment, both the control server 120 and the bot control device 110C are configured to instruct the bot 110 to cause the bot 110 to classify the order of cases of the outgoing flow independent of the order of cases taken from the storage area by the bot 110 forming the pick face. Thus, the control server 120 and / or the bot controller 110C are configured to set the flow of outgoing cases, at least in part, together with the bot 110's classification of cases commonly carried by the bot 110, and decoupled from the order of picking cases from the storage by the bot 110. As described below, the bot 110 is configured to transfer a first pick face PCF1 having any suitable number of case units therein from the pick-up aisle 130A and place a second pick face PCF2, different from the first pick face PCF1, on a common surface CS (such as a rack shelf RTS) of a transfer / hand-over station TS (or buffer station BS) common to the bot 110 and the lift 150B. This may be referred to as a classification of the outgoing flow by the bot of the transfer station (and / or buffer station) for purposes of explanation. Also, as described below, the first and second pick faces, in one embodiment, have at least one case unit common to both the first and second pick faces.In one embodiment, as described herein, the bot 110 is configured to build a first pick face on the fly, for example, during a traverse from a first pick position in the pick path 130A to the placement of a second pick face at the transfer / handover station TS in a multiple pick / place sequence. The controller 110C of the bot 110 is configured to effect the on-the-fly construction of the first pick face PCF1 (or any other pick face picked by the bot 110). In one embodiment, the bot 110 is configured to pick / build a pick face PCF3 different from the first pick face PCF1 and place this different pick face PCF3 on a shelf (such as another rack shelf RTS stacked above or below the rack shelf forming a common surface CS) of the transfer / handover station TS (or buffer station BS). The bot 110 includes case operations as described herein. The bot is configured to pick up the first pick face PCF1, further pick up a second pick face PCF2 (forming a different pick face PCF3) from one or more case units of the rack shelf RTS (or other location such as a storage shelf in the pick-up aisle), and place the different pick face PCF3 on the common surface CS. As can be understood, the lift 150B is configured in one embodiment to pick up the second pick face PCF2 from the transfer / delivery station TS. In another embodiment, the lift 150 is configured to pick up a third pick face PCF4 from the common surface CS (such as the rack transfer shelf RTS) of the transfer / delivery station TS (or buffer station BS) as described herein, where the third pick face PCF4 is different from the first and second pick faces PCF1, PCF2, and a common case is common to the first, second and third pick faces PCF1, PCF2, PCF4.

[0084] In one aspect of the disclosed embodiment, as can be understood, in a multiple pick / place sequence, multiple case units are transported and manipulated substantially simultaneously within the loading section 110PL, 4110PL of the bot 110 or lift 150 to effect multiple pick / place sequences in accordance with a predetermined order removal sequence for the outbound flow of the case units, and to further increase the throughput of the storage and pick system 100. With further reference to FIG. 1, the bot 110 or lift 150B receives pick and place instructions, for example, from the control server 120 (and / or the warehouse management system 2500), and the bot controller 110C executes those instructions, or the lift 150B executes those instructions (e.g., under the control of the control server 120 or the lift controller) to form the ordered multiple picks. Here, the bot 110 enters the common aisle 130A1, for example, from the transfer deck 130B, to make a single or common path through the common aisle 130A1, during which the bot 110 retrieves two or more case units according to a predetermined order ejection sequence (FIG. 15, block 1201A), or a lift moves the load handling devices LHD, LHD1, LHD2 in the Z direction to retrieve one or more case units from one or more transfer stations TS according to a predetermined order ejection sequence (FIG. 14A, block 1201AB). In one aspect, the operation of case units CU,7,5 is the sorting of case units (i.e., removal and placement of case units according to a predetermined load removal sequence) in which the case units are positioned on the transfer arms 110PA,LHDA,LHDB for removal / placement of the case units and / or positioned such that the case units remain on the transfer arms 110PA,LHDA,LHDB without being transferred while other case units are transferred to or from the transfer arms 110PA,LHDA,LHDB.Here, the bot 110 moves in the direction of the arrow XC through the common pick-up aisle 130A1 and stops at a predetermined storage space 130S1, and the bot 110 uses the common transfer arm 110PA to pick up one or more case units from the predetermined storage space 130S1 ( FIG. 15 , block 120B), or the load handling devices LHD, LHD1, LHD2 move in the Z direction according to a predetermined order removal sequence and stop at a predetermined shelf 7000A-7000F of the interface station TS, and the load handling devices LHD, LHD1, LHD2 use the common transfer arms LHDA, LHDB to pick up one or more case units from the interface station TS ( FIG. 15 , block 120B). One or more case units are retrieved from a given shelf 7000A-7000F of station TS (FIG. 14A, block 1201BB) and, as described in more detail below, the placement of the case units on a common transfer arm 110PA, LHDA, LHDB corresponds to a given order ejection sequence (e.g., the case units are sorted on the fly, e.g., during transport with the bot 110, to the interface station, without changing direction or in one stroke, during a single or unidirectional pass / traverse of the lift 150, although the movement of the lift 150 is not necessarily a continuous movement).

[0085] As an example of case operations on a bot 110 or lift 150, referring also to Figures 5B, 6, 10, 10A-10E (note that case units 5, 7 are shown coupled to the loading section of the lift, and it should be understood that in the examples described herein, case units 5, 7 are similarly coupled to the loading section of the bot), a case unit 7 is removed from a case unit holding position (e.g., from a storage space 130S in a common pick-up aisle or a shelf 7000D of an interface station to effect ordered multiple pick-ups, or in other embodiments, from any suitable lift interface station TS and / or case unit buffer station BS located on the pick-up aisle or transfer deck) and transported into the loading section 110PL, 4110PL (Figure 14A, block 1201BB and Figure 15, block 1201B). When the case unit 7 is transferred into the loading section 110PL, 4110PL, the pusher bar 110PR, 4110PR may be pre-positioned adjacent to the fence 110PF, 4110PF (Figure 14A, block 1204B and Figure 15, block 1204) so ​​that it is positioned between the case unit 7 and the fence 110PF, 4110PF when the case unit 7 is lowered for transfer to the rollers 110RL, 4110RL (Figure 14A, block 1205B and Figure 15, block 1205). The pusher bar 110PR, 4110PR is actuated to push the case unit 7 (resting on the rollers 110RL, 4110RL) in the Y direction towards the rear (e.g., rear) 402, 4402 of the loading section 110PL, 4110PL so that the case unit 7 contacts the alignment surfaces 273JS, 4273JS (FIG. 10) of the tines 273A-273E, 4273A, 4273E and is aligned with the rear 402 of the loading section 110PL (FIG. 14A, block 1210B and FIG. 15, block 1210).

[0086] In one aspect, the bot 110 continues to traverse the common pick-up aisle 130A1 in the same direction XC (e.g., so that all of the case units in an ordered multiple pick-up are picked in a common path of the pick-up aisle using the bot 110 moving in a single direction) and stops at another different predetermined storage space 130S according to a predetermined order ejection sequence, or the load handling devices LHD, LHD1, LHD2 continue to traverse the mast 4002 in the same direction (e.g., so that all of the case units in an ordered multiple pick-up are picked in a common path of the vertical stack of the interface station TS using the load handling devices LHD, LHD1, LHD2 moving in a single direction) and stops at another different predetermined shelf 7000A-7000F of a different interface station TS according to a predetermined order ejection sequence. As described above, the pusher bar 110PR, 4110PR remains facing the case unit(s) 7 (e.g., gripping the case unit 7) during transport of the case unit(s) between case unit holding positions (including storage spaces and interface station shelves 7000A-7000F) so that the case unit(s) remain in a predetermined position on the back surface 402, 4402 of the loading section 110PL, 4110PL (and / or in a predetermined longitudinal position in the X direction) relative to the reference coordinate system REFL of the bot 110 or the reference coordinate system REFL of the lift 150B1 (Figure 14A, block 1215B and Figure 15, block 1215).For example, to retrieve a subsequent case unit from another storage space 130S2 of the common retrieval aisle 130A1, or from another interface station shelf 7000B, the pusher bar 110PR, 4110PR is moved in the Y direction to release the case unit(s) 7, and the extension axes of the lift and transfer arms 110PA, LHDA, LHDB are actuated to retrieve another case unit(s) 5 from the other storage space 130S2 or another interface station shelf 7000B (or in other aspects, for example, from any suitable lift interface / transfer station TS as described above, and / or buffer station BS) (Figure 14A, block 1220B and Figure 15, block 1220). While the case unit(s) 5 are being removed, the pusher bar 110PR, 4110PR is positioned adjacent to the loading section 110PL, 4110PL in the Y direction so as to be located between the case unit 7 and the alignment surfaces 273JS, 4273JS of the tines 273A-273E, 4273A-4273E (FIG. 14A, block 1225B and FIG. 15, block 1225). The case unit(s) is transferred into the loading section and lowered / placed onto the rollers 110RL, 4110RL such that the case units 7, 5 are positioned along the Y axis relative to each other (FIG. 14A, block 1230 and FIG. 15, block 1230). The pusher bar 110PR, 4110PR is actuated in the Y direction to push the case units 7, 5 towards the fence 110PF, 4110PF to align the case units 7, 5 forward (FIG. 14A, block 1234B and FIG. 15, block 1234) and to grasp / hold the case units 7, 5 for transport (FIG. 14A, block 1235B and FIG. 15, block 1235).As can be seen, in one embodiment, the case units 7, 5 are placed together in the case unit holding location, while in other embodiments, the case units 7, 5 are sorted and, for example, transported and placed in separate locations of a common case unit holding location, separate case unit holding locations, or separate interface stations 160TS, 160TSA, as described in more detail below (FIG. 14A, block 1240B and FIG. 15, block 1240). For example, referring also to FIGS. 7-9, the bot 110 carrying the ordered multiple pick-up load transfers the ordered multiple pick-up case units to one or more interface stations TS corresponding to the output lifts 150B1, 150B2.

[0087] As can be appreciated, in one embodiment in which a bot 110 "parallel parks" into an interface station TS (FIG. 7) or turns into a pier 130BD (FIG. 8), the spacing between bots traveling on the high speed bot transport path HSTP of the transfer deck 130B (FIG. 2A) is such that a bot interacting with the interface station TS can slow down and turn into the interface station TS substantially without interference from and / or with another bot 110 traveling along the transfer deck 130B. In other embodiments, since the transfer deck 130B is substantially open and configured for non-deterministic passage of bots 110 across and along the transfer deck 130B as described above, bots traveling on the transfer deck may maneuver around bots turning into the interface station. When multiple pick-up case units are placed at different positions, for example, on a common buffer shelf 7000A-7000L of the interface / handover station of lifts 150B1, 150B2, bot 110 places a first one of the case units 5 (for illustrative purposes, corresponding to pick face 7 of FIG. 9 and including a single case unit in this example) in a first position on buffer shelf 7000B and a second one of the case units 7 (for illustrative purposes, corresponding to pick face 5 of FIG. 9 and including a single case unit in this example) in a second position on buffer shelf 7000B. When multiple pick-up case units are placed at a common case unit holding position, bot 110 places both case units 7, 5 together (e.g., pick faces) in a common position, for example, on buffer shelf 7000A (for illustrative purposes, corresponding to pick face 9 of FIG. 9 and including two case units in this example).

[0088] When the case units 7, 5 are sorted for placement at a common case unit holding position, at a respective position at a common case unit holding position (or at a common interface station 160TS, 160TSA, such as for placement of consecutive but chronologically spaced case units), or at different case unit holding positions (or at different interface stations 160TS, 160TSA) (FIG. 14A, block 1250B and FIG. 15, block 1250), the case units 7, 5 are separated from each other in the loading section 110PL, 4110PL. For example, the pick head 270, 4270 of the transfer arm 110PA, LHDA, LHDB can be moved in the Z direction to lift the case units 7, 5 from the rollers 110RL, 4110RL by a sufficient amount to allow the pusher bar 110PR, 4110PR to pass directly underneath the case units (FIG. 16, block 1250A). Once the case units 7, 5 are lifted, the pusher bars 110PR, 4110PR are positioned along the Y direction (see FIG. 10E) so as to be located between the case units 7, 5 (FIG. 16, block 1250B). The pick heads 270, 4270 are lowered so that the case units 7, 5 are transferred to the rollers 110RL, 4110RL and the pusher bars 110PR, 4110PR are inserted between the case units 7, 5 (FIG. 16, block 1250C). The pusher bar 110PR, 4110PR is moved in the Y direction (e.g., to separate the case units) to move the case unit 7 toward the rear 402, 4402 of the loading section 110PL, 4110PL (e.g., relative to the alignment surfaces 273JS, 4273JS of the tines 273A-273E, 4273A-4273E or any other suitable position), while the case unit 5 remains in front of the loading section 110PL, 4110PL adjacent the fence 110PF, 4110PF (e.g., as shown in FIG. 10C) ( FIG. 16 , block 1250D).As can be appreciated, when a case unit is held against the alignment surfaces 273JS, 4273JS of the tines during transport, the pusher bar is moved in the Y direction (e.g., to separate the case unit) to move the case unit 5 toward the front 401, 4401 of the loading section 110PL, 4110PL (e.g., relative to the fence 110PF, 4110PF or any other suitable position), while the case unit 7 remains at the rear of the loading section 110PL, 4110PL adjacent the alignment surfaces 273JS, 4273JS. The pusher bar 110PR, 4110PR may be moved in the Y direction to realign the case unit 5 against the fence 110PF, 4110PF to position the case unit on the tines 273A-273E, 4273A-4273E for placement in the case unit holding position (FIG. 16, block 1250E). As can be appreciated, with the case unit 7 positioned substantially against the alignment surfaces 273JS, 4273JS of the tines 273A-273E, 4273A-4273E (e.g., of the pick head 270, 4270), the case unit 5 can be placed in the case unit holding position (FIG. 16, block 1250F) substantially without interference from the case unit 7, e.g., the case unit 7 avoids contact with case units placed in the case unit holding position. The case unit 7 is lowered / transferred back into the loading section 110PL, 4110PL (e.g., by retracting and lowering the transfer arm 110PA, 4110PA) (FIG. 16, block 1250G). The pusher bar 110PR, 4110PR, which is pre-positioned between the alignment surface 273JS, 4273JS and the case unit 7, pushes the case unit 7, which is positioned on the rollers 110RL, 4110RL, against the fences 110PF, 4110PF to align the case unit 7 forward for placement at another case unit holding position (e.g., different from the holding position in which the case unit 5 is positioned) (Figure 16, block 1250H).The pusher bar 110PR, 4110PR remains facing the case unit 7 to grip the case unit (e.g., by a fence) during transport to the other case unit holding position (FIG. 16, block 1250I). The pusher bar 110PR, 4110PR moves away from the case unit 7 and the transfer arm is actuated to raise and extend the pick head 270, 4270 to place the case unit 7 at the other case unit holding position (FIG. 16, block 1250J).

[0089] An example of a case unit(s) transfer process of the bot 110 includes multiple pick and place operations of case unit(s) with on-the-fly sorting of the case units to create a mixed pallet load MPL (as shown in FIG. 1C ) in accordance with a predetermined order ejection sequence and / or in accordance with instructions to process one or more customer orders, for example, where the case units are sequenced for placement into one or more bags, totes, or other containers TOT at operator station 160EP (as shown in FIG. 21 ), as described in connection with FIGs. 9 and 11-13 , in accordance with aspects of the disclosed embodiments. For example, referring to FIG. 11, a customer order may request that case unit 7 be delivered to output lift 150B1 and that case unit 5 also be delivered to output lift 150B1 (note that in other aspects, a customer order may request that case units carried by a common bot 110 be delivered to different output lifts 150B1, 150B2 (FIG. 9) such that the transfer of case units carried by a common bot 110 to different output lifts occurs in a manner substantially similar to that described herein). In aspects of the disclosed embodiment described herein, output lift 150B1 (e.g., each of output lifts 150B1, 150B2 of a storage and retrieval system / order processing system) defines a mixed case pick face processing path or aisle in which mixed case pick faces are issued from the storage array to loads that enter and exit the processing path in substantially the same order. As can be appreciated, while the loading and unloading lifts 150A, 150B are described as vertically reciprocating lifts, it should be understood that in other embodiments the loading and unloading lifts 150A, 150B are any suitable transport modules for transporting case pick faces to and from the storage structure 130.For example, in other embodiments, the lift modules 150A, 150B are one or more of a reciprocating lift, any suitable automated material handling system, a conveyor, a bot, a turntable, a roller bed, a multi-level conveyor (e.g., a paternoster conveyor), operating synchronously or asynchronously. To efficiently utilize each bot 110 in the storage and retrieval system 100, a control device such as the control server 120 determines which retrieval aisle the case units 5, 7 are located in. The control device also determines which incoming case unit ICU should be stored in the retrieval aisle from which the case units 5, 7 (e.g., outgoing case units) are retrieved. The control device sends instructions to the bots 110 on the level where the case units 5, 7 are located to retrieve one or more incoming case unit ICUs from the interface stations TS of one or more lift modules 150A in a manner substantially similar to that described above (FIG. 17, block 1400A). The bot 110 picks up the case unit ICU (FIG. 17, block 1420) and transports the case unit to one or more storage spaces 130 in one or more pick-up aisles 130A2 (FIG. 17, block 1421), where at least one of the pick-up aisles in which the incoming case unit is located includes one of the outgoing case units 5, 7. As can be understood, if the incoming case unit is located in another storage location 130S, the incoming case unit is sorted as described above (FIG. 17, block 1425), and one or more case units are transferred to one case unit holding location, such as the storage space 130S or a buffer (FIG. 17, block 1430), while the case units that are not transferred are returned to the loading section of the bot 110 for transfer to another case unit holding location (FIG. 17, block 1435).

[0090] As can be seen, the outgoing case units 5, 7 are located in the same or different pick-up aisles and are picked up by one bot 110 or different bots 110 depending on the proximity of the outgoing case units and the predetermined storage location of the incoming case units. For example, referring to FIG. 11, the bot 110 picks up the incoming case unit ICU from the interface station TS of the lift module 150A (in a manner similar to that described above) for placement in pick-up aisle 130A2, the pick-up aisle in which case unit 5 is located. In this example, case unit 7 is located in pick-up aisle 130A1. After placement of the incoming case unit ICU, the bot continues to move along the pick-up aisle 130A2 in a common path (e.g., a single traversal of the pick-up aisle in a single direction) to pick up the outgoing case unit 5 (FIG. 17, block 1400). If it is more efficient to have a single bot 110 retrieve multiple case units, the outgoing case unit 5 is justified on the bot 110 as described above (FIG. 17, block 1405), and the bot moves to the location of another case unit, such as the outgoing case unit 7 in aisle 130A1 (note that if a second outgoing case unit is located in a common aisle with the first outgoing case unit, both outgoing case units are retrieved on a common path in the retrieval aisle by the common transfer arm 110PA (FIG. 6) of the bot 110). The second outgoing case unit 7 is retrieved by the common transfer arm 110PA (FIG. 17, block 1410), and both case units 5, 7 are transported and placed in one or more of the peripheral buffer stations BS and interface stations TS of the pick face transport system, such as the lift module 150B, in a manner substantially similar to that described above with respect to the placement of the incoming case units (FIG. 17, blocks 1420-1435).After picking up each outgoing case (FIG. 17, block 1400), if it would be more efficient to have two different bots 110 pick up each of the case units 5, 7, the case units are picked up (FIG. 17, block 1420) and transported and placed in one of the peripheral buffer stations BS or interface stations TS of the outgoing lift 150B as described herein (FIG. 17, blocks 1421-1435). In one embodiment, when an outgoing case unit, such as case unit 5, is placed in the peripheral buffer station BS, a different bot 110 than the bot that placed the case unit 5 in the peripheral buffer station BS transports the case unit 5 to the interface station TS, while in other embodiments, the same bot 110 returns to the peripheral buffer station BS to transport the case unit 5 to the interface station TS. In aspects of the disclosed embodiments described herein, the buffer station BS and / or transfer station TS (e.g., at least one pick face delivery station) commonly support pick faces of two or more mixed cases that define a portion of the pick faces of the mixed cases exiting the storage array / structure 130 that enter the fulfillment path in a sequence of pick faces ordered based on a predetermined load-filling sequence. In one or more of the aspects of the disclosed embodiments described herein, the buffer station BS and / or transfer station TS form a common pick face transfer interface to the outgoing lift 150B1 such that the commonly supported pick faces are commonly retrieved by the outgoing lift 150B1. In one or more aspects of the disclosed embodiments described herein, the buffer station BS and / or transfer station TS each commonly support two or more mixed case pick faces that define a portion of the pick faces of the mixed cases issuing from the storage array (for illustration purposes only, see pick faces 1-4 in FIG. 9 ), with the pick faces ordered based on a predetermined load-filling sequence.In one or more aspects of the disclosed embodiments described herein, the pick faces of the mixed cases that define a portion of the pick faces of the mixed cases exiting the storage array / structure 130 in an order sequence and that are commonly supported on the buffer station BS and / or transfer station TS are based on a sequence of ordered pick faces on another buffer station BS and / or transfer station TS of another delivery path (see, for example, the mixed cases exiting from the exit lift 150B2). In one or more aspects of the disclosed embodiments, any suitable controller, such as controller 120, is configured to communicate with the bot 110 and effect placement of the pick faces on the buffer station BS and / or transfer station TS based on the sequence of ordered pick faces.

[0091] In one embodiment, the outgoing case units are picked up and transported as a unit (e.g., pick face) by a common transfer arm 110PA (FIG. 6) of the bot 110. Referring again now to FIG. 12, a customer order may request that case unit 7 be transported to the output lift 150B1 and that case unit 5 also be transported to the output lift 150B1 (note that in other embodiments, a customer order may also request that case units carried by the common bot 110 be transported to different output lifts 150B1, 150B2 (FIG. 9) such that the transport of case units carried by the common bot 110 to different output lifts occurs in a manner substantially similar to that described herein). As described above, the controller determines which incoming case unit ICU should be stored in the pick-up aisle from which case units 5, 7 (e.g., outgoing case units) are picked. The control device sends a command to the bot 110 on the level where the case units 5, 7 are located to retrieve one or more incoming case units ICU as a whole (e.g., pick face) from the interface station TS of the lift module 150A in a manner substantially similar to that described above (FIG. 17, block 1400A). The bot 110 grabs the pick face PF1 (FIG. 17, block 1420) and transports it to the storage space 130 in the retrieval aisle 130A2 (FIG. 17, block 1421), and the outgoing case units 5, 7 position and place the pick face PF1 in the storage space 130S (FIG. 17, block 1430). Note that the flow does not proceed to block 1435 of FIG. 17 in this example because the entire pick face is transferred to the common storage space and no case units are left on the bot.

[0092] After placing the incoming pick face PF1, the bot 110 continues to move through the aisle 130A2 in a common path (e.g., a single trip through the pick-up aisle in a single direction) to a storage space holding outgoing case units 5, 7 (which are arranged on the storage shelf adjacent to each other so as to be picked up simultaneously as the outgoing pick face PF2). The bot 110 picks up the pick face PF2 by a common transfer arm 110PA (FIG. 6) (FIG. 17, block 1415), grasps the pick face PF2 (FIG. 17, block 1420), and transports the pick face PF2 to the outgoing lift 150B1 (FIG. 17, block 1421). In one embodiment, the case units 5, 7 of the pick face PF2 are placed together in one of the peripheral buffer stations BS or transfer stations TS (FIG. 17, block 1430). In another embodiment, the case units 5, 7 of the pick face are separated and aligned (in a manner similar to that described above) for placement in different locations (FIG. 17, block 1425). For example, the bot 110 places the case unit 7 in the peripheral buffer station BS (FIG. 17, block 1430), returns the case unit 5 to the loading area of ​​the bot 110 (FIG. 17, block 1435), grasps the case unit 5 (FIG. 17, block 1420), transports the case unit 5 to the interface station TS (FIG. 17, block 1421), and transfers the case unit 5 to the interface station (FIG. 17, block 1430).

[0093] In another embodiment, referring to FIG. 13, the outgoing case units 5, 7 are removed from different storage positions in the common aisle 130A2 by the common transfer arm 110PA (FIG. 6) of the bot 110. Here, the bot 110 transfers one or more incoming case units ICU to one or more storage positions in the manner described above, at least one of the incoming case units ICU being located in the removal aisle 130A2 common to the outgoing case units 5, 7. After placing at least one incoming case unit in a predetermined storage position 130S in the aisle 130A2, the bot 110 continues to move through the removal aisle 130A1 on the common path of the removal aisle 130A2 and removes the case unit 5 from the storage space 130S1 in the manner described above (FIG. 17, block 1400). The case unit 5 is aligned on the bot 110 to the rear of the loading section 110PL as described above (FIG. 17, block 1405). The bots 110 continue to move through the pick-up aisle 130A1 on a common path of the pick-up aisle and pick up the case unit 7 from the different storage space 130S2 by the common transfer arm 110PA such that both case units 7, 5 are positioned adjacent to each other on the common transfer arm 110PA (FIG. 17, block 1410). As can be appreciated, in one embodiment, the controller 110C is configured to effect the pick-up of the case units in any suitable order, such as, for example, in the opposite order to the order in which the case units were placed.

[0094] In this multiple pick-up example, the case unit holding locations correspond to storage spaces 130S in the pick-up aisle 130, but in other embodiments the case unit holding locations include input lift modules 150A1, 150A2 (where direct transfer between the bots and the lifts occurs), interface or peripheral buffer stations TS, BS for interacting with the input lift modules 150A1, 150A2 (where indirect transfer between the lift modules and the bots occurs), and the storage space 130S (note that pick-up by the bot 110 from the interface stations TS and input lift module 150A is delivered into the storage rack array in a just-in-time manner such that case units required for a given order pick-up sequence are not placed in the storage space 130S but are delivered substantially directly to the output lifts 150B1, 150B2).

[0095] The bot 110 grasps both case units 7 and 5 in the loading section 110PL in the manner described above and exits the removal aisle 130A1 (FIG. 17, block 1420). The bot moves along the transfer deck 130B and interacts with the discharge lift 150B1 (FIG. 17, block 1421). The bot separates the case units 7 and 5 in the loading section 110PL as described above (FIG. 17, block 1425), in any suitable manner, such as, for example, so that the case unit 7 is aligned at the front of the loading section 110PL and the case unit 5 is aligned at the rear of the loading section 110PL. The case unit 7 is transferred to the peripheral buffer station BS (FIG. 17, block 1430). The bot retracts the transfer arm 110PA to return the case unit 5 to the loading section 110PL (FIG. 17, block 1435) and grasps the case unit 5 (FIG. 17, block 1420). The case unit 5 is transported to the interface station TS of the output lift 150B1 (FIG. 17, block 1421), aligned to the front of the loading section 110PL as described above (FIG. 17, block 1425), and transferred to the transfer station TS as described above (FIG. 17, block 1430). In other embodiments, depending on the predetermined case unit output sequence, the bot 110 places both case units 7, 5 at a common location / position, such as one of the output lifts 150B1, 150B2. For example, the pick face 20 (FIG. 9) on the shelf 7000H may include both case units 7, 5 such that the bot 110 places both case units at a single position on the shelf 7000H as a multiple case unit pick face. As can be appreciated, the case units placed at the buffer station BS are transferred to the interface station TS by the bot 110 in one embodiment, or by any suitable conveyor connecting the buffer station BS to the interface station TS in other embodiments.In one aspect, when a case unit is transported by a bot 110 from a buffer station BS to an interface station TS, the transport is a timely transport, for example, such that the bot 110 travels along a transport deck on a route for another task (e.g., transporting a pick face to storage, sorting the pick face, transporting a pick face from storage, etc.) and travels past the buffer station BS, stops to retrieve a pick face from the buffer station BS, and transports the pick face to the interface station TS during the process of performing another task.

[0096] In the examples described herein, the transfer of the case unit between the bot 110 and the lift 150 occurs passively through the interface station TS as described above. As an example of transfer, referring to FIG. 18, the autonomous transport vehicle is positioned relative to the interface station TS in a manner similar to that described above with respect to the slats 1210S and / or the positioning features 130F (FIG. 18, block 1800). The transfer arm 110PA (e.g., end effector) of the bot 110 extends to transfer the pick face to the interface station TS where the fingers 273A-273E of the transfer arm 110PA interact with, for example, the slats 1210S of the interface station TS (FIG. 18, block 1801). As can be understood and as described above, multiple pick faces may be positioned on the interface station TS for simultaneous and independent transfer to the lift 150 (e.g., multiple individual pick faces are held on the interface station simultaneously). The lift 150 is moved to position the load handling devices LHD, LHDA, LHDB adjacent to the interface station TS (FIG. 18, block 1802). The load handling devices LHD, LHDA, LHDB are extended to lift the pick face from the interface station and transfer the pick face to the lift 150 where the fingers 4273 of the load handling devices LHD, LHDA, LHDB interact with the slats 1210S of the interface station TS, for example, in the manner described above with respect to FIG. 4B (FIG. 18, block 1803). As can be appreciated, the interface station TS has no moving parts and the transfer of the pick face between the bot 110 and the lift 150 through the interface station TS is a passive transfer. As can also be appreciated, the transfer of the pick face from the lift 150 to the bot 110 may occur in a manner substantially opposite to that described above with respect to FIG. 18.

[0097] In one embodiment, the pick face constructed (e.g., in the manner described above) by the bot 110 that is transported (e.g., placed) to, for example, the interface station TS (and / or the buffer station BS) is not identical to the pick face removed from the interface station TS (and / or the buffer station BS) by the lift 150. For example, referring to FIG. 9, the bot 110 forms a first pick face including individual pick faces 7 and 5 from the storage space 130S in the rack module RM (e.g., FIG. 2A) (FIG. 19, block 1900). The bot 110 transports and places the first pick face, for example, on shelf 7000B of the interface station TS for transport to the lift 150 (FIG. 19, block 1910). As can be appreciated, in this example, the individual pick faces 5, 7 (e.g., forming a first pick face) are placed on a common shelf 7000B for illustrative purposes only, but in other embodiments, the individual pick faces 5, 7 are placed on different shelves 7000A-7000F such that the pick face placed on the shelf by the bot 110 is different from the first pick face but includes at least one common case unit with the first pick face. For example, the first pick face is decomposed such that a different pick face including the individual pick face 5 is placed on shelf 7000B, while another different pick face including the individual pick face 7 is placed on, for example, shelf 7000H. A lift such as lift 150B1 retrieves a second pick face from one or more shelves 7000A-7000F (e.g., common to both the bot 110 and lift 150B1) of the transfer station TS (FIG. 19, block 1920). Here, the second pick face is different from the first pick face but includes at least one of the individual pick faces 5, 7 such that at least one case unit is common between the first pick face and the second pick face.

[0098] Similarly, in one embodiment, the pick face transferred (e.g., placed) by the inbound lift 150 (see lift 150A in FIG. 1 ) to, for example, the interface station TS (and / or buffer station BS) is not the same as the pick face removed by the bot 110 from the interface station TS (and / or buffer station BS). In one embodiment, the control server 120 is configured to instruct the bot 110 to effect a classification of cases of the inbound flow (which may also be referred to as warehouse replenishment or inbound stream) at the transfer station TS (and / or buffer station BS) by the bot 110 forming the pick face, independent of the order of removal of the cases from the input station by the lift 150. In one embodiment, the bot controller 110C is configured to instruct the bot 110 to effect a classification of cases of the inbound flow at the transfer station TS (and / or buffer station BS) by the bot 110 forming the pick face, independent of the order of removal of the cases from the input station by the lift 150. In yet another aspect, both the control server 120 and the bot controller 110C are configured to instruct the bot 110 to effect a classification of cases of the inbound flow at the transfer station TS (and / or buffer station BS) by the bot 110 forming the pick face, independent of the order of picking of the cases from the input station by the lift 150. Thus, the control server 120 and / or the bot controller 110C are configured to set the flow of inbound cases, at least in part, together with the bot 110's classification of cases commonly carried by the bot 110, and decoupled from the order of picking of the cases by the lift 150. For purposes of explanation, this may be referred to as classification of cases of the inbound flow by the bot 110 at the transfer station TS (and / or buffer station BS).For example, referring to FIG. 9A, first pick faces are transferred from input station 160IN by input conveyor 160CB to one or more lifts 150A1, 150A2 (FIG. 20, block 2000). In this example, one of the first pick faces includes a combination of individual pick faces 5, 7, while the other first pick face includes a combination of individual pick faces 20, 22. Lift 150A1 places each of the first pick faces 5, 7 on shelf 7000B of interface station TS, while lift 150A2 places the other respective first pick face 20, 22 on shelf 7000H of another interface station TS on the same storage level 130L (FIG. 20, block 2010). The bot 110 constructs or retrieves a second pick face from the interface station TS such that a first pick face placed on the shelf 7000B, 7000H by the lift 150A1, 150A2 (e.g., common to both the bot 110 and the respective lift 150A) is different from the second pick face, but the second pick face includes at least one case unit in common with the first pick face (FIGS. 20, 2020). For example, the first pick faces 5, 7 are disassembled such that a different pick face including an individual pick face 5 (or an individual pick face 7) is retrieved by the bot 110, and / or the other first pick faces 20, 22 are disassembled such that a different pick face including an individual pick face 20 (or an individual pick face 22) is retrieved by the bot 110. Here, the second pick face is different from the first pick face but includes at least one of the individual pick faces of the first pick face such that at least one case unit is common between the first pick face and the second pick face. As can be appreciated, the second pick face may be disassembled by the bot such that a pick face placed on at least one storage shelf by the bot 110 is different from the second pick face and at least one case unit is common between the second pick face and a pick face placed on at least one storage shelf.

[0099] In one embodiment, referring again to Figure 5A, a lift having multiple independently operable load handling devices LHD1, LHD2 picks and places case units from two or more interface stations TS at separate storage levels 130LA, 130LB and transfers them to the same or separate outbound conveyor interface stations TS (e.g., when one or more outbound conveyor transfer stations TS handling a common lift 150 are stacked one on top of the other), where each of the independently operable load handling devices LHD1, LHD2 picks and places a case unit from an interface station shelf 7000A-7000F and delivers the picked case unit to an outbound conveyor 160CB in a manner substantially similar to that described above with respect to Figures 10F, 10G, and 10H. In one embodiment, each load handling device LHD1, LHD2 includes a single transfer arm LHDA, LHDB (see FIGS. 4A, 5A) or two or more single transfer arms LHDA, LHDB (see FIG. 5) (e.g., one load handling device includes a single transfer arm while the other load handling device LHD includes two or more transfer arms, or both load handling devices include a single transfer arm, or both load handling devices include two or more transfer arms). In one embodiment, load handling devices LHD1, LHD2 include the sorting and alignment mechanism described with respect to FIG. 5B.

[0100] The output lifts 150B1, 150B2 transport the ordered multiple pick(s) placed on the shelves 7000A-7000L by the bots 110 to the output station 160UT also according to a predetermined order output sequence. For example, referring again to FIG. 9, pick faces 1-22 are picked by the lifts 150B1, 150B2 in an ordered order, whereby pick faces 1-22 are delivered to the output station 160UT in a predetermined order sequence (e.g., order output sequence) of picked items required to form the mixed pallet load MPL (e.g., as indicated by the numbers associated with each case unit / pick face illustrated in FIG. 9) and / or according to an order to fulfill one or more customer orders, e.g., where the case units are sequenced for placement into one or more bags, totes, or other containers TOT at the operator station 160EP (as shown in FIG. 21). Thus, each of the interface stations TS of each lift 150B1, 150B2 forms a buffer section which holds one or more case units until they are required to form a mixed pallet load and are removed by the respective lift 150B1, 150B2.

[0101] Referring to FIG. 22, in accordance with aspects of the disclosed embodiment, storage spaces arranged on racks along a pick-up aisle are provided (FIG. 22, block 1600). A multi-level deck is also provided (FIG. 22, block 1610), with at least one deck level of the multi-level deck communicating with each aisle, and the multi-level deck and the aisle defining a rolling surface for the autonomous transport vehicle at each level of the multi-level deck. Racks of the multiple rack levels are accessed from respective rolling surfaces common to the multiple rack levels (FIG. 22, block 1620), and the racks are arranged along at least one aisle at each level of the multi-level deck. In one aspect, the vertical pitch between the rack levels is different for each aisle section. In one aspect, the vertical pitch between at least two rack levels of each aisle section is associated with another vertical pitch between at least two other rack levels of another aisle section of each aisle, such that the autonomous transport vehicle provides multiple pick-up of order sequences in a common aisle path. In one aspect, a vertical pitch between at least two rack levels in a respective aisle portion is related to another vertical pitch between at least two other rack levels in another aisle portion of the respective aisle such that the vertical pitch and the other vertical pitch substantially fill the vertical space between the multiple deck levels with stored items.

[0102] As can be appreciated, the load handling devices described above are configured to hold pick faces (one or more) of different sizes and / or having any number of case units. For illustrative purposes only, FIG. 5D illustrates a load handling device LHDA holding two pick faces PCKFC1, PCKFC2. It should be understood that the load handling device LHDA is shown for illustrative purposes only, and that any of the load handling devices described herein are configured in a substantially similar manner as described with respect to the load handling device LHDA. Here, pick face PCKFC1 includes a single case unit CU1, while pick face PCKFC2 includes two case units CU2, CU3 such that it is larger than PCKFC1. In other embodiments, pick faces PCKFC1, PCKFC2 have any suitable size and include any suitable number of case units. As can be appreciated, while two pick faces PCKFC1, PCKFC2 are shown held on the load handling device LHDA, in other embodiments the load handling device LHDA may hold any suitable number of pick faces, such as three or more or one. The placement of pick faces PCKFC1, PCKFC2 (and the case units / totes therein) is, in one embodiment, placed on the inbound or outbound lifts 150A, 150B according to a predetermined sequence. By way of example, pick faces PCKFC1, PCKFC2 are similar to one or more of pick faces 5 described above.

[0103] According to one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes at least one autonomous transport vehicle, a transfer deck having a plurality of travel lanes and defining a non-deterministic transport surface for the at least one autonomous transport vehicle, at least one reciprocating lift, and at least one pick face handover station connected to the transfer deck and providing interaction between the at least one autonomous transport vehicle on the transfer deck and the at least one reciprocating lift such that pick faces are transferred between the at least one reciprocating lift and the at least one autonomous transport vehicle.

[0104] In accordance with one or more aspects of the disclosed embodiment at least one pick face transfer station is a passive transfer station.

[0105] In accordance with one or more aspects of the disclosed embodiment at least one pick face transfer station is configured to simultaneously support independent pick face loads.

[0106] In accordance with one or more aspects of the disclosed embodiment, the automated storage and retrieval system further includes a retrieval aisle connected to the transfer deck, and the at least one pick face transfer station is disposed on an opposite side of the transfer deck from the retrieval aisle.

[0107] In accordance with one or more aspects of the disclosed embodiment, the at least one pick face transfer station is offset from the multiple transfer lanes such that interaction of the autonomous transport vehicle with the at least one pick face transfer station is non-deterministic with respect to movement of the autonomous transport vehicle along the multiple travel lanes.

[0108] According to one or more aspects of the disclosed embodiment, the at least one autonomous transport vehicle includes an end effector configured to transfer pick faces to and from the at least one autonomous transport vehicle, the at least one reciprocating lift includes an end effector configured to transfer pick faces to and from the at least one reciprocating lift, the at least one pick face transfer station includes a fixed pick face support surface configured to interact with at least one of the end effectors of the at least one autonomous transport vehicle and the end effector of the at least one reciprocating lift, and the at least one reciprocating lift is rigidly attached to the transfer deck.

[0109] In accordance with one or more aspects of the disclosed embodiment, the automated storage and retrieval system further includes a buffer station having at least one shelf that buffers the pick face between retrieval and placement of the pick face by the autonomous guided vehicle.

[0110] In accordance with one or more aspects of the disclosed embodiment a buffer station is disposed adjacent to the at least one pick face transfer station.

[0111] In accordance with one or more aspects of the disclosed embodiment, the buffer station includes an array of shelves stacked vertically on top of each other, each shelf configured to buffer a pick face between retrieval and placement of the pick face by the autonomous guided vehicle.

[0112] In accordance with one or more aspects of the disclosed embodiment, the buffer station is connected to at least one pick face transfer station by at least one autonomous guided vehicle.

[0113] In accordance with one or more aspects of the disclosed embodiment, at least one pick face transfer station includes a positioning feature to enable at least one autonomous guided vehicle to position itself relative to the at least one pick face transfer station.

[0114] According to one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes at least one autonomous transport vehicle having a transport vehicle end effector configured to transfer pick faces to and from the at least one autonomous transport vehicle, a transfer deck having a plurality of travel lanes and defining a non-deterministic transport surface for the at least one autonomous transport vehicle, at least one reciprocating lift having a lift end effector configured to transfer pick faces to and from the at least one reciprocating lift, and at least one pick face transfer station configured to interact with at least one of the transport vehicle end effector and the lift end effector to effect transfer of pick faces between the at least one pick face transfer station and at least one of the at least one autonomous transport vehicle and the at least one reciprocating lift.

[0115] In accordance with one or more aspects of the disclosed embodiment at least one pick face transfer station is a passive transfer station.

[0116] In accordance with one or more aspects of the disclosed embodiment at least one pick face transfer station is configured to simultaneously support independent pick face loads.

[0117] In accordance with one or more aspects of the disclosed embodiment, the automated storage and retrieval system further includes a retrieval aisle connected to the transfer deck, and the at least one pick face transfer station is disposed on an opposite side of the transfer deck from the retrieval aisle.

[0118] In accordance with one or more aspects of the disclosed embodiment, the at least one pick face transfer station is offset from the multiple transfer lanes such that interaction of the autonomous transport vehicle with the at least one pick face transfer station is non-deterministic with respect to movement of the autonomous transport vehicle along the multiple travel lanes.

[0119] In accordance with one or more aspects of the disclosed embodiment, the at least one pick face transfer station includes a pick face support surface configured to interact with at least one of the transport vehicle end effector and the lift end effector.

[0120] In accordance with one or more aspects of the disclosed embodiment, the automated storage and retrieval system includes a buffer station disposed adjacent to at least one pick face transfer station.

[0121] In accordance with one or more aspects of the disclosed embodiment, the buffer station is connected to at least one pick face transfer station by at least one autonomous guided vehicle.

[0122] In accordance with one or more aspects of the disclosed embodiment, at least one pick face transfer station includes a positioning feature to enable at least one autonomous transport to position itself relative to the at least one pick face transfer station.

[0123] According to one or more aspects of the disclosed embodiment, the method includes using an autonomous transport vehicle to place a first pick face at a pick face transfer station and using a shuttle lift to retrieve a second pick face, different from the first pick face, from the pick face transfer station, wherein the pick face transfer station is common to the autonomous transport vehicle and the shuttle lift, and at least one case unit is common between the first pick face and the second pick face.

[0124] In accordance with one or more aspects of the disclosed embodiment, the method further includes constructing a pick face adjacent to the at least one storage shelf using the autonomous guided vehicle, wherein the pick face constructed adjacent to the at least one storage shelf is different from the first pick face, and at least one case unit is common between the first pick face and the pick face constructed adjacent to the at least one storage shelf.

[0125] According to one or more aspects of the disclosed embodiment, the method includes retrieving a first pick face from a storage shelf using an autonomous transport vehicle, buffering the first pick face on a stationary shelf at a pick face delivery station using the autonomous transport vehicle, forming a second pick face on the stationary shelf, and retrieving the second pick face from the stationary shelf using a reciprocating lift, wherein the second pick face is different from the first pick face and comprises two or more cases in an order sequence corresponding to a predetermined case unloading order sequence for the mixed cases, and the first pick face and the second pick face have at least one case in common.

[0126] According to one or more aspects of the disclosed embodiment, the pick face transfer station includes two or more vertically stacked stationary shelves, where placing a first pick face on the stationary shelves includes placing the first pick face on one of the two or more vertically stacked stationary shelves, and removing a second pick face from the stationary shelves includes removing the second pick face from one of the two or more vertically stacked stationary shelves.

[0127] According to one or more aspects of the disclosed embodiment, the second pick face retrieved from the stationary shelf by the reciprocating lift is different from the first pick face placed by the autonomous transport vehicle, and the stationary shelf is common to the second pick face retrieved by the reciprocating lift and the first pick face placed by the autonomous transport vehicle.

[0128] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes a three-dimensional storage array having multiple levels of racks in aisles, the aisles configured for movement of autonomous transport vehicles in the aisles, a transfer deck having a non-deterministic transport surface, the autonomous transport vehicles traveling on the non-deterministic transport surface, and the non-deterministic transport surface having two or more parallel travel lanes connecting the aisles.

[0129] In accordance with one or more aspects of the disclosed embodiment, two or more parallel travel lanes are juxtaposed along a common non-deterministic conveying surface between opposite ends of a transfer deck.

[0130] In accordance with one or more aspects of the disclosed embodiment the walkway is joined to the transfer deck on one side of the transfer deck.

[0131] In accordance with one or more aspects of the disclosed embodiment, the transfer deck has a deck storage rack distributed along one side different from the other side of the transfer deck such that at least a portion of the transfer deck is interposed between the deck storage rack and the aisle.

[0132] In accordance with one or more aspects of the disclosed embodiment, the automated storage and retrieval system further includes a lift, with the deck storage rack positioned along the other side in communication with the autonomous transport vehicle from the transfer deck and with the lift.

[0133] According to one or more aspects of the disclosed embodiment, the method includes placing a first pick face at a pick face transfer station using a reciprocating lift and retrieving a second pick face from the pick face transfer station using an autonomous transport vehicle, the pick face transfer station being common to the autonomous transport vehicle and the reciprocating lift, and at least one case unit being common between the first pick face and the second pick face.

[0134] According to one or more aspects of the disclosed embodiment, the method further includes placing a pick face on the at least one storage shelf using the autonomous guided vehicle, wherein the pick face placed on the at least one storage shelf is different from a second pick face, and at least one case unit is common between the second pick face and the pick face placed on the at least one storage shelf.

[0135] In accordance with one or more aspects of the disclosed embodiment, the first pick face is different from the second pick face.

[0136] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes at least one autonomous transport vehicle, a storage array having a rack aisle and a plurality of storage rack modules disposed along the rack aisle, a transfer deck defining a transfer surface for the at least one autonomous transport vehicle, at least one reciprocating lift, and at least one pick face transfer station coupled to the transfer deck and providing interaction between the at least one autonomous transport vehicle on the transfer deck and the at least one reciprocating lift, wherein the at least one autonomous transport vehicle transfers a first pick face transfer between the rack aisle and the at least one pick face transfer station. The at least one autonomous transport vehicle is configured to transport a pick face and place a second pick face, different from the first pick face, on a common surface of the at least one pick face delivery station that is common to both the at least one autonomous transport vehicle and the at least one reciprocating lift, the second pick face having a case that is a common case with the first pick face, and the at least one reciprocating lift is configured to retrieve a third pick face from the common surface of the at least one pick face delivery station, the third pick face being different from the first and second pick faces, and the common case being common to the first, second, and third pick faces.

[0137] According to one or more aspects of the disclosed embodiment, the at least one autonomous transport vehicle is configured to construct a first pick face on the fly during a traverse from a first pick position in the rack aisle to placement of a second pick face at the at least one pick face transfer station.

[0138] In accordance with one or more aspects of the disclosed embodiment, at least one autonomous guided vehicle includes a controller configured to cause construction of a first pick face.

[0139] According to one or more aspects of the disclosed embodiment, at least one autonomous guided vehicle is configured to transport another pick face from the rack aisle and place the other pick face on a shelf of the at least one pick face transfer station, and then transport a second pick face from the shelf to the common surface.

[0140] According to one or more aspects of the disclosed embodiment, a product order processing system includes at least one autonomous transport vehicle configured to hold and transport pick faces, a storage array having a transfer deck defining a transport surface for the at least one autonomous transport vehicle, at least one other pick face transport system connected to the transfer deck, and at least one pick face transfer station positioned adjacent to the transfer deck, where the at least one pick face transfer station is configured to transfer pick faces between the at least one autonomous transport vehicle and the at least one other pick face transport system, where the at least one other pick face transport system defines a processing course of mixed case pick faces to be issued from the storage array to a load fill, and the at least one pick face transfer station commonly supports two or more of the mixed case pick faces defining a portion of the mixed case pick faces to be issued from the storage array to enter the processing course in an order sequence of the pick faces based on a predetermined sequence of the load fill.

[0141] According to one or more aspects of the disclosed embodiment, at least one pick face transfer station forms a common pick face transfer interface for at least one other pick face transport system such that a commonly supported pick face is commonly retrieved by at least one other pick face transport system.

[0142] In accordance with one or more aspects of the disclosed embodiment, each of the at least one pick face delivery station commonly supports two or more mixed case pick faces that define a portion of the mixed case pick faces to be issued from the storage array in an order sequence of the pick faces based on a predetermined sequence of load fills.

[0143] In accordance with one or more aspects of the disclosed embodiment, the mixed case pick faces that define a portion of the mixed case pick faces that are issued from the storage array in an order sequence and that are commonly supported on at least one pick face transfer station are based on an order sequence of pick faces on another pick face transfer station of another processing course.

[0144] In accordance with one or more aspects of the disclosed embodiment, the product order processing system further includes a controller in communication with the at least one autonomous guided vehicle, the controller configured to cause placement of pick faces onto the at least one pick face delivery station based on an order sequence of the pick faces.

[0145] In accordance with one or more aspects of the disclosed embodiment the at least one other pick face transport system includes a reciprocating lift.

[0146] In accordance with one or more aspects of the disclosed embodiment, the at least one pick face transfer station has a stationary shelf that provides transfer of pick faces between the at least one autonomous transport vehicle and the at least one other pick face transport system.

[0147] According to one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes a pick face transfer station, an autonomous transported vehicle configured to place a first pick face at the pick face transfer station, and a shuttle lift configured to retrieve a second pick face different from the first pick face from the pick face transfer station, wherein the pick face transfer station is common to the autonomous transported vehicle and the shuttle lift, and at least one case unit is common between the first pick face and the second pick face.

[0148] In accordance with one or more aspects of the disclosed embodiment, the automated storage and retrieval system further includes at least one storage shelf, and the autonomous transport vehicle is further configured to construct a pick face adjacent to the at least one storage shelf, the pick face constructed adjacent to the at least one storage shelf being different from the first pick face, and at least one case unit being common between the first pick face and the pick face constructed adjacent to the at least one storage shelf.

[0149] According to one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes a storage shelf, a pick face transfer station including a stationary shelf, an autonomous transport vehicle configured to retrieve a first pick face from the storage shelf, buffer the first pick face on the stationary shelf of the pick face transfer station, and form a second pick face on the stationary shelf, where the second pick face is different from the first pick face and comprises two or more cases in an order sequence corresponding to a predetermined case unloading order sequence for mixed cases, and the first pick face and the second pick face have at least one case in common, and a shuttle lift configured to retrieve the second pick face from the stationary shelf.

[0150] According to one or more aspects of the disclosed embodiment, the pick face delivery station includes two or more vertically stacked stationary shelves, the autonomous transport vehicle is configured to buffer a first pick face on one of the two or more vertically stacked stationary shelves by placing the first pick face on the one of the two or more vertically stacked stationary shelves, and the shuttle lift is configured to retrieve a second pick face from the stationary shelf by retrieving a second pick face from one of the two or more vertically stacked stationary shelves.

[0151] According to one or more aspects of the disclosed embodiment, the second pick face retrieved from the stationary shelf by the reciprocating lift is different from the first pick face placed by the autonomous transport vehicle, and the stationary shelf is common to the second pick face retrieved by the reciprocating lift and the first pick face placed by the autonomous transport vehicle.

[0152] In accordance with one or more aspects of the disclosed embodiment, the lift includes at least one load handling device configured to reciprocate along a lift axis, and a drive section connected to the load handling device and configured to move the load handling device along the lift axis, the load handling device including a frame forming a loading section including a load support surface having a common elevator, the common elevator configured to hold one or more pick faces at the common elevator of the load support surface, and at least one transfer arm movably attached to the frame, the one or more pick faces carried in unison by the load support surface of the at least one load handling device defining an order sequence of pick faces on the at least one load handling device according to a predetermined case unloading order sequence for mixed cases.

[0153] In accordance with one or more aspects of the disclosed embodiment, the lift further includes a controller connected to the drive section, the controller configured to effect a defined order sequence of pick faces on the at least one load handling device according to a predetermined case unloading order sequence for the mixed cases.

[0154] In accordance with one or more aspects of the disclosed embodiment at least one pick face of the one or more pick faces is a multi-case unit pick face.

[0155] In accordance with one or more aspects of the disclosed embodiment, the lift is configured to position one or more pick faces according to a predetermined case unloading order sequence.

[0156] In accordance with one or more aspects of the disclosed embodiment, at least one transfer arm is common to two or more pick faces, and the transfer arm is configured to hold two or more pick faces adjacent to one another.

[0157] In accordance with one or more aspects of the disclosed embodiment, the at least one transfer arm comprises two independently operable transfer arms configured to individually transfer the pick face to and from the load handling device.

[0158] In accordance with one or more aspects of the disclosed embodiment, the at least one load handling device includes two independently operable load handling devices configured to individually transport the pick faces.

[0159] In accordance with one or more aspects of the disclosed embodiment, the load handling device further includes an alignment member disposed within the loading section, and the control device is configured to control the combined movement of the alignment member and the transfer arm to effect sorting of two or more case pick faces carried within the loading section.

[0160] In accordance with one or more aspects of the disclosed embodiment, the lift further includes an alignment member connected to the drive section and the control device, the alignment member movably mounted to the frame, and the transfer arm and the alignment member are each independently movable relative to one another.

[0161] In accordance with one or more aspects of the disclosed embodiment, the controller is configured to control the drive section and effect movement of the alignment member and the transfer arm such that on-the-fly sorting is effected by holding at least one of the two or more pick faces within the loading section while another one of the two or more pick faces is transferred to or from the loading section.

[0162] In accordance with one or more aspects of the disclosed embodiment, the lift is a high-speed lift having a pick face transfer processing speed approximately equal to a pick face transfer processing speed of an autonomous guided vehicle that transfers the pick face to the shuttle lift.

[0163] In accordance with one or more aspects of the disclosed embodiment at least one load handling device is mounted to the mast for reciprocating movement along a length of the mast.

[0164] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system lift includes a frame and at least one load carriage having a carriage frame with a drive axis and forming a load section configured to hold one or more load items, the at least one load carriage having multiple independent degrees of freedom transfer arms positioned on a first load axis for movement along a first load axis transverse to the drive axis, the multiple independent degrees of freedom transfer arms being at least partially positioned within the load section, the multiple independent degrees of freedom transfer arms and load section configured to provide on-the-fly sorting of one or more load items carried within the load section.

[0165] In accordance with one or more aspects of the disclosed embodiment, the at least one load carriage further includes an alignment member positioned within the load section for movement along a second load axis transverse to the first load axis.

[0166] In accordance with one or more aspects of the disclosed embodiment, the lift further includes a control device connected to the alignment member and the at least one transfer arm, the control device configured to control the combined movement of the alignment member and the at least one transfer arm to provide on-the-fly sorting of one or more load items carried within the loading section.

[0167] In accordance with one or more aspects of the disclosed embodiment, the alignment member and the at least one transfer arm are each independently movable relative to one another.

[0168] According to one or more aspects of the disclosed embodiment, the control device is configured to effect movement of the alignment member and at least one transfer arm such that the alignment member is inserted between two of the one or more load items to cause physical separation of the two of the one or more load items.

[0169] In accordance with one or more aspects of the disclosed embodiment the alignment member is configured to bidirectionally move one or more load items along the second axis within the load section.

[0170] In accordance with one or more aspects of the disclosed embodiment, the controller is configured to control movement of the alignment member and the at least one transfer arm such that sorting is effected by holding at least one of the one or more load items within the loading section while another one of the one or more load items is transferred to or from the loading section.

[0171] In accordance with one or more aspects of the disclosed embodiment, the at least one load carriage comprises two independently operable load carriages positioned side by side on the mast to move along the mast independently of one another.

[0172] In accordance with one or more aspects of the disclosed embodiment, the at least one transfer arm includes a plurality of load holding positions arranged to hold a load in at least a side-by-side arrangement to effect simultaneous transfer of the load to and from the at least one transfer arm.

[0173] In accordance with one or more aspects of the disclosed embodiment, the transfer arm includes a plurality of load supporting tines configured for transfer of a load therethrough to a load holding location of the storage and retrieval system.

[0174] In accordance with one or more aspects of the disclosed embodiment the drive shaft comprises a common mast on which the multiple independent degrees of freedom transfer arms are disposed.

[0175] According to one or more aspects of the disclosed embodiment, the storage and retrieval system includes at least one transfer arm configured to hold at least one pick face, at least one bot configured to transfer at least one pick face to and from the at least one transfer station, at least one load handling device mounted for reciprocating movement along a lift axis, at least one transfer arm movably mounted to the frame, and a drive section connected to the load handling device and configured to move the load handling device along the lift axis, wherein the at least one load handling device includes a frame forming a load section with a load support surface in communication with the at least one transfer station and having a common elevator configured to hold the one or more pick faces on a common elevator of the load support surface, wherein the one or more pick faces carried in unison by the load support surface of the at least one load handling device define an order sequence of the pick faces on the at least one load handling device according to a predetermined case unloading order sequence of the differently configured pick faces.

[0176] In accordance with one or more aspects of the disclosed embodiment, the storage and retrieval system further includes a controller connected to the drive section, the controller configured to effect a defined order sequence of pick faces on the at least one load handling device according to a predetermined case removal order sequence between the differently configured pick faces.

[0177] In accordance with one or more aspects of the disclosed embodiment at least one pick face of the one or more pick faces is a multi-case unit pick face.

[0178] In accordance with one or more aspects of the disclosed embodiment, at least one load handling device is configured to position one or more pick faces according to a predetermined case unloading order sequence.

[0179] In accordance with one or more aspects of the disclosed embodiment, at least one transfer arm is common to two or more pick faces, and the transfer arm is configured to hold two or more pick faces adjacent to one another.

[0180] In accordance with one or more aspects of the disclosed embodiment, the at least one transfer arm comprises two independently operable transfer arms configured to individually transfer the pick face to and from the load handling device.

[0181] In accordance with one or more aspects of the disclosed embodiment, the at least one load handling device includes two independently operable load handling devices configured to individually transport the pick faces.

[0182] In accordance with one or more aspects of the disclosed embodiment, the load handling device further includes an alignment member disposed within the loading section, and the control device is configured to control the combined movement of the alignment member and the transfer arm to effect sorting of two or more case pick faces carried within the loading section.

[0183] In accordance with one or more aspects of the disclosed embodiment, the at least one load handling device further includes an alignment member connected to the drive section and the control device, the alignment member movably mounted to the frame, and the transfer arm and the alignment member are each independently movable relative to one another.

[0184] In accordance with one or more aspects of the disclosed embodiment, the controller is configured to control the drive section and effect movement of the alignment member and the transfer arm such that on-the-fly sorting is effected by holding at least one of the two or more pick faces within the loading section while another one of the two or more pick faces is transferred to or from the loading section.

[0185] In accordance with one or more aspects of the disclosed embodiment, the at least one load handling device is a high-speed lift having a pick face transfer processing speed approximately equal to a pick face transfer processing speed of an autonomous guided vehicle that transfers the pick face to the at least one load handling device.

[0186] In accordance with one or more aspects of the disclosed embodiment, the order sequence of the differently configured pick faces is independent of the order sequence of the pick faces at the transfer station.

[0187] In accordance with one or more aspects of the disclosed embodiment, the method includes using a common platform of the lift to retrieve pick faces according to an order sequence on the common platform, and using the common platform to substantially simultaneously place the pick faces in the order sequence at an output pick face holding location.

[0188] In accordance with one or more aspects of the disclosed embodiment the pick face includes a mixing case unit.

[0189] In accordance with one or more aspects of the disclosed embodiment the pick face includes two or more distinct pick faces.

[0190] In accordance with one or more aspects of the disclosed embodiment, the pick faces are removed from a common level of the pick face holding position.

[0191] In accordance with one or more aspects of the disclosed embodiment the pick face is retrieved from multiple levels of pick face holding positions.

[0192] In accordance with one or more aspects of the disclosed embodiment, the method includes retrieving two or more pick faces using a common platform of a lift, and using the lift to provide on-the-fly classification of the two or more pick faces.

[0193] In accordance with one or more aspects of the disclosed embodiment, sorting two or more pick faces on the fly includes traversing a stack of pick face holding positions in a common direction using a common platform.

[0194] In accordance with one or more aspects of the disclosed embodiment, the method includes retrieving at least one pick face using a common platform of a lift and, in a single offloading step, placing the at least one pick face at an outgoing pick face holding position using the lift, wherein the at least one pick face has a classified position at the offload.

[0195] In accordance with one or more aspects of the disclosed embodiment at least one pick face includes a mixed case unit.

[0196] In accordance with one or more aspects of the disclosed embodiment the at least one pick face includes two or more different pick faces.

[0197] In accordance with one or more aspects of the disclosed embodiment, at least one pick face is retrieved from a common level of pick face holding positions.

[0198] In accordance with one or more aspects of the disclosed embodiment, at least one pick face is retrieved from multiple levels of pick face holding positions.

[0199] In accordance with one or more aspects of the disclosed embodiment, the lift includes at least one load handling device mounted for reciprocating movement along a lift axis, at least one transfer arm movably mounted to the frame, a drive section connected to the load handling device and configured to move the load handling device along the lift axis, and a controller connected to the drive section and configured to effect retrieval of two or more pick faces using a common load support platform and on-the-fly sorting of the two or more pick faces using the common load support platform, wherein the load handling device includes a frame forming a load section with a common load support platform configured to hold one or more pick faces on the common load support platform.

[0200] In accordance with one or more aspects of the disclosed embodiment, the control device is configured to effect the removal of two or more pick faces in an order sequence using a common load support platform, and the placement of two or more pick faces in an order sequence using the common load support platform to an outgoing pick face holding position.

[0201] In accordance with one or more aspects of the disclosed embodiment, the control device is configured to provide on-the-fly sorting of two or more pick faces, where a common load support platform traverses a stack of pick face holding positions in a common direction.

[0202] According to one or more aspects of the disclosed embodiment, the control device is configured to cause placement of two or more pick faces to an output pick face holding position in a single offload step, the two or more pick faces having an assorted placement at the offload.

[0203] According to one or more aspects of the disclosed embodiment, a product order processing system includes a plurality of decks arranged on separate levels to define a multi-level deck, at least one autonomous transport vehicle disposed on each of the multi-level decks and configured to hold and transport pick faces on each deck, at least one lift disposed to traverse, connect, and raise and lower pick faces from two or more levels of the multi-level deck, and at least one pick face transfer station on each deck that allows interaction between the autonomous transport vehicle on the deck and the at least one lift to effect transfer of pick faces between the autonomous transport vehicle and the at least one lift, wherein the at least one lift defines a processing stream of mixed case pick faces issued from the multi-level deck to a load fill, wherein at least one of the processing streams has an order sequence of streaming pick faces, and the order sequence of the streaming pick faces is based on another processing stream.

[0204] In accordance with one or more aspects of the disclosed embodiment the load pack includes mixed case pick faces arranged in a predetermined pick face load order sequence.

[0205] In accordance with one or more aspects of the disclosed embodiment, an order sequence of streaming pick faces from at least one stream is associated with a given pick face load order sequence.

[0206] In accordance with one or more aspects of the disclosed embodiment, an order sequence of streaming pick faces from at least one stream is combined with pick faces from other processing streams to fill a load fill in a given pick face load order sequence.

[0207] In accordance with one or more aspects of the disclosed embodiment, at least one pick face from another processing stream that is combined with an order sequence of streaming pick faces from at least one stream forms part of a consecutively ordered pick face of a given pick face load order sequence.

[0208] In accordance with one or more aspects of the disclosed embodiment, the at least one lift includes a first lift, and the other processing stream is defined by another one of the at least one lift independent from the first lift.

[0209] According to one or more aspects of the disclosed embodiment, the first lift has a lift platform arranged to support two or more pick faces thereon, and the first lift is configured to effect retrieval or placement of the two or more pick faces using the lift platform on a common lift elevator according to an order sequence of the streaming pick faces.

[0210] In accordance with one or more aspects of the disclosed embodiment, the first lift results in the removal or placement of two or more pick faces substantially simultaneously.

[0211] In accordance with one or more aspects of the disclosed embodiment, the product order processing system further includes a storage array comprising a storage rack having pick face storage locations arranged on multiple levels corresponding to separate levels of the multi-level deck.

[0212] In accordance with one or more aspects of the disclosed embodiment, a product order processing system includes a plurality of decks arranged on separate levels to define a multi-level deck, at least one autonomous transport vehicle disposed on each of the multi-level decks and configured to hold and transport a pick face on each deck, a first lift disposed to traverse and connect two or more levels of the multi-level deck and to raise and lower the pick face from the multi-level deck, a second lift disposed to traverse and connect two or more levels of the multi-level deck and to raise and lower the pick face from the multi-level deck, and an autonomous transport vehicle on the deck to effect transfer of the pick face between the autonomous transport vehicle and the first and second lifts. The system includes at least one pick face transfer station on each deck for interaction between the vehicle and first and second lifts, the first lift defining a first process stream of mixed case pick faces issued from the multi-level deck to the load fill, the second lift defining a second process stream of mixed case pick faces issued from the multi-level deck to the load fill, the first process stream having a first order sequence of streaming pick faces, the second process stream having a second order sequence of streaming pick faces, the first order sequence of streaming pick faces capturing the second order sequence of streaming pick faces and associated with the load fill order sequence.

[0213] In accordance with one or more aspects of the disclosed embodiment the load pack includes mixed case pick faces arranged in a predetermined pick face load order sequence.

[0214] In accordance with one or more aspects of the disclosed embodiment, at least one of a first order sequence of streaming pick faces from a first processing stream and a second order sequence of streaming pick faces from a second processing stream is associated with a predetermined pick face load order sequence.

[0215] In accordance with one or more aspects of the disclosed embodiment, a first order sequence of streaming pick faces from a first processing stream is combined with pick faces from a second order sequence of streaming pick faces from a second processing stream to fill a load fill in a given pick face load order sequence.

[0216] In accordance with one or more aspects of the disclosed embodiment, at least one pick face from a second processing stream that is combined with a first order sequence of streaming pick faces from the first processing stream forms part of consecutively ordered pick faces of a given pick face load order sequence.

[0217] In accordance with one or more aspects of the disclosed embodiment, the at least one lift includes a first lift, and the second processing stream is defined by another one of the at least one lift independent from the first lift.

[0218] According to one or more aspects of the disclosed embodiment, the first lift has a lift platform positioned to support two or more pick faces thereon, and the first lift is configured to effect retrieval or placement of the two or more pick faces using the lift platform on a common lift elevator in response to a first order sequence of streaming pick faces.

[0219] In accordance with one or more aspects of the disclosed embodiment, the first lift results in the removal or placement of two or more pick faces substantially simultaneously.

[0220] In accordance with one or more aspects of the disclosed embodiment, the product order processing system further includes a storage array comprising a storage rack having pick face storage locations arranged on multiple levels corresponding to separate levels of the multi-level deck.

[0221] In accordance with one or more aspects of the disclosed embodiment, a method of product order fulfillment includes providing a plurality of decks arranged on separate levels defining a multi-level deck; disposing at least one autonomous transport vehicle on each of the multi-level decks, and using the at least one autonomous transport vehicle to hold and transport pick faces on each deck; raising and lowering the pick faces from the multi-level decks using at least one lift that traverses and connects two or more levels of the multi-level decks; providing transfer of the pick faces between the autonomous transport vehicles and the at least one lift using at least one pick face transfer station on each deck that interacts between the autonomous transport vehicles on the decks and the at least one lift; and defining a processing stream of mixed case pick faces to be issued from the multi-level deck to a load fill using the at least one lift, wherein at least one of the processing streams has an order sequence of streaming pick faces, and the order sequence of the streaming pick faces is based on another processing stream.

[0222] In accordance with one or more aspects of the disclosed embodiment the load packing comprises mixed case pick faces, and the method includes arranging the mixed case pick faces in a predetermined pick face loading order sequence.

[0223] In accordance with one or more aspects of the disclosed embodiment, an order sequence of streaming pick faces from at least one stream is associated with a given pick face load order sequence.

[0224] In accordance with one or more aspects of the disclosed embodiment, the method further includes combining an order sequence of streaming pick faces from at least one stream with pick faces from other processing streams to fill the load fill in a predetermined pick face load order sequence.

[0225] In accordance with one or more aspects of the disclosed embodiment, the method further includes forming a portion of consecutively ordered pick faces of a given pick face load order sequence using at least one pick face from another processing stream that is combined with the order sequence of streaming pick faces from the at least one stream.

[0226] In accordance with one or more aspects of the disclosed embodiment, the at least one lift includes a first lift, and the method further includes defining a other processing stream by another one of the at least one lift independent from the first lift.

[0227] According to one or more aspects of the disclosed embodiment, the first lift has a lift platform positioned to support two or more pick faces thereon, and the method further includes using the first lift to effect retrieval or placement of the two or more pick faces using a lift platform on a common lift elevator in accordance with an order sequence of the streaming pick faces.

[0228] In accordance with one or more aspects of the disclosed embodiment, further including effecting removal or placement of two or more pick faces substantially simultaneously with the first lift.

[0229] In accordance with one or more aspects of the disclosed embodiment, the method further includes providing a storage array comprising a storage rack having pick face storage locations arranged on a plurality of levels corresponding to separate levels of the multi-level deck.

[0230] According to one or more aspects of the disclosed embodiment, a product order processing system includes a plurality of decks arranged on separate levels to define a multi-level deck; at least one autonomous transport vehicle disposed on each of the multi-level decks and configured to hold and transport pick faces on each deck; at least one lift disposed to traverse, connect, and raise and lower pick faces from two or more levels of the multi-level deck; and at least one pick face buffer station on each deck that provides interaction between the at least one autonomous transport vehicle on the deck and the at least one lift to provide transfer of pick faces between the autonomous transport vehicle and the at least one lift, wherein the at least one lift defines a processing stream of mixed case pick faces that are streamed out from the multi-level deck to a load fill, and the at least one pick face buffer station of at least one of the multi-level decks commonly supports two or more of the mixed case pick faces that define a portion of the streaming pick faces in an order sequence of the streaming pick faces based on a predetermined sequence of the load fill.

[0231] In accordance with one or more aspects of the disclosed embodiment, at least one pick face buffer station forms a common pick face transfer interface for at least one lift such that a commonly supported pick face is commonly retrieved by the at least one lift.

[0232] In accordance with one or more aspects of the disclosed embodiment, at least one pick face buffer station on two or more of the multi-level decks each commonly supports two or more of the multi-level decks defining a portion of the streaming pick faces in an order sequence of the streaming pick faces based on a predetermined sequence of load fills.

[0233] In accordance with one or more aspects of the disclosed embodiment, a mixed case pick face that defines a portion of a streaming pick face in an order sequence commonly supported on a buffer station is based on the order sequence of a pick face on another buffer station of a different processing stream.

[0234] In accordance with one or more aspects of the disclosed embodiment, the product order processing system further includes a controller in communication with the at least one autonomous guided vehicle, the controller configured to cause placement of pick faces into the at least one pick face buffer station based on an order sequence of the streaming pick faces.

[0235] It should be understood that the above description is merely illustrative of aspects of the disclosed embodiments. Various alternatives and modifications may be devised by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, the aspects of the disclosed embodiments are intended to include all such alternatives, modifications, and variations that fall within the scope of the appended claims. Moreover, the fact that different features are recited in different dependent or independent claims does not mean that a combination of these features cannot be used to advantage, and such combinations remain within the scope of the present invention.

Claims

1. A frame, at least one payload carriage; An automated storage and retrieval system, comprising: The at least one payload carriage is a carriage frame including a drive shaft and defining a loading section configured to hold one or more pick faces; at least one independent degree of freedom transfer arm disposed on a first payload axis for movement along a first payload axis transverse to the drive axis, the at least one independent degree of freedom transfer arm being disposed at least partially within the load section; having the at least one independent degree of freedom transfer arm and the loading section are configured to provide on-the-fly sorting of the one or more pick faces carried in the loading section upon unloading of the one or more pick faces at an outgoing pick face holding location; Automated storage and retrieval system, storage lift.

2. The automated storage and retrieval system output lift of claim 1 , wherein the at least one independent degree of freedom transfer arm is common to two or more pick faces such that the transfer arm is configured to hold two or more pick faces adjacent to one another.

3. The automated storage and retrieval system output lift of claim 1, wherein the automated storage and retrieval system output lift is a high-speed lift having a pick face transfer processing speed approximately equal to a pick face transfer processing speed of an autonomous transport vehicle that transfers a pick face to the automated storage and retrieval system output lift.

4. The automated storage and retrieval system output lift of claim 1 , wherein said at least one load carriage is mounted to a mast for reciprocating movement along a length of said mast.

5. 2. The automated storage and retrieval system output lift of claim 1, wherein the at least one independent degree of freedom transfer arm includes at least one pick face holding position arranged to hold the pick face in at least a side-by-side arrangement to effect simultaneous transfer of the pick face to and from the at least one independent degree of freedom transfer arm.

6. The automated storage and retrieval system output lift of claim 1 , wherein the at least one independent degree of freedom transfer arm includes a plurality of pick face support tines configured for transfer by passage of a pick face to a pick face holding location of the storage and retrieval system.

7. The automated storage and retrieval system output lift of claim 1 , wherein the drive shaft comprises a common mast on which the at least one independent degree of freedom transfer arm is disposed.

8. A frame, at least one payload carriage; An automated storage and retrieval system, comprising: The at least one payload carriage is a carriage frame including a drive shaft and defining a loading section configured to hold one or more pick faces; at least one independent degree of freedom transfer arm disposed on a first payload axis for movement along a first payload axis transverse to the drive axis, the at least one independent degree of freedom transfer arm being disposed at least partially within the load section; having Automated storage and retrieval system, storage lift.

9. 10. The automated storage and retrieval system output lift of claim 8, wherein the at least one independent degree of freedom transfer arm is common to two or more pick faces such that the transfer arm is configured to hold two or more pick faces adjacent one another.

10. The automated storage and retrieval system output lift of claim 8, wherein the automated storage and retrieval system output lift is a high-speed lift having a pick face transfer processing speed approximately equal to a pick face transfer processing speed of an autonomous transport vehicle that transfers a pick face to the automated storage and retrieval system output lift.

11. 9. The automated storage and retrieval system output lift of claim 8, wherein said at least one load carriage is mounted to a mast for reciprocating movement along a length of said mast.

12. 10. The automated storage and retrieval system output lift of claim 8, wherein the at least one independent degree of freedom transfer arm includes at least one pick face holding position arranged to hold the pick face in at least a side-by-side arrangement to effect simultaneous transfer of the pick face to and from the at least one independent degree of freedom transfer arm.

13. 10. The automated storage and retrieval system output lift of claim 8, wherein the at least one independent degree of freedom transfer arm includes a plurality of pick face support tines configured for transfer by a pick face passing through the pick face to a pick face holding location of the storage and retrieval system.

14. The automated storage and retrieval system output lift of claim 8 , wherein the drive shaft comprises a common mast on which the at least one independent degree of freedom transfer arm is disposed.

15. providing a frame for an automated storage and retrieval system output lift; providing at least one payload carriage, said at least one payload carriage comprising: a carriage frame including a drive shaft and defining a loading section configured to hold one or more pick faces; at least one independent degree of freedom transfer arm disposed on a first payload axis for movement along a first payload axis transverse to the drive axis, the at least one independent degree of freedom transfer arm being disposed at least partially within the load section; providing at least one payload carriage having a providing on-the-fly sorting of the one or more pick faces carried in the loading section upon unloading of the one or more pick faces at an outgoing pick face holding location by the at least one independent degree of freedom transfer arm and the loading section; A method comprising:

16. The method of claim 15 , wherein the at least one independent degree of freedom transfer arm is common to two or more pick faces for holding two or more pick faces adjacent to one another.

17. 16. The method of claim 15, wherein the automated storage and retrieval system output lift is a high speed lift having a pick face transfer processing speed approximately equal to a pick face transfer processing speed of an autonomous guided vehicle that transfers a pick face to the automated storage and retrieval system output lift.

18. The method of claim 15 further comprising mounting the at least one payload carriage to a mast for reciprocating movement along a length of the mast.

19. 16. The method of claim 15, wherein the at least one independent degree of freedom transfer arm includes at least one pick face holding position arranged to hold the pick face in at least a side-by-side arrangement, the method further including effecting simultaneous transfer of the pick face to and from the at least one independent degree of freedom transfer arm.

20. The method of claim 15 , wherein the at least one independent degree of freedom transfer arm includes a plurality of pick face support tines configured for transfer of a pick face therethrough to a pick face holding location of a storage and retrieval system.

21. The method of claim 15 , wherein the drive shaft comprises a common mast on which the at least one independent degree of freedom transfer arm is disposed.

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