System and applicable method for collecting items from a storage container using a robotic operator

Abstract

To avoid or at least reduce congestion of a storage container around a delivery column.SOLUTION: The present invention is an automated warehouse system including an automated warehouse grid 104 and a delivery system 140. The automated warehouse grid includes a container handling vehicle rail system and delivery columns 119 and 120. The delivery system includes a remote-controlled delivery vehicle 30. The remote-controlled delivery vehicle includes a container carrier adapted to support a storage container 106. The delivery vehicle is further adapted to transport the storage container between a first location and a second location represented by a delivery port. The second location includes a robot operator 160' for handling a product item in the storage container.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to an automated storage and retrieval system including an automated storage grid and a delivery system. The system further includes a remotely operated delivery vehicle for transporting storage containers between the automated storage grid and a second location. The second location includes a robotic operator for handling product items in the storage containers. The present invention also relates to an associated method of transporting storage containers between the automated storage grid and the second location, where the robotic operator is located at the second location. [Background technology]

[0002] Figures 1A and 1C disclose a typical prior art automated warehouse system 1 with a framework structure 100. Figures 1B and 1D disclose prior art container handling vehicles 200, 300, respectively, that operate the system 1 disclosed in Figures 1A and 1C.

[0003] The framework structure 100 includes a number of upright members 102 and, optionally, a number of horizontal members 103 that support the upright members 102. The members 102, 103 may typically be made from metal, for example from extruded aluminum profiles.

[0004] The framework structure 100 defines a storage grid 104, which includes storage columns 105 arranged in rows, within which storage containers 106 (also known as receptacles) are stacked one on top of the other to form a stack 107. The storage grid 104 includes a number of grid columns 112, each defined by four of the upright members 102. Most of the grid columns are also referred to as storage columns 105, within which storage containers 106 (also known as receptacles) are stacked one on top of the other to form a stack 107.

[0005] Each storage container 106 can typically hold multiple product items (not shown), and the product items in a storage container 106 can be the same or can be of different product types depending on the application.

[0006] The storage grid 104 prevents horizontal movement of the storage containers 106 in the stack 107 and guides vertical movement of the storage containers 106, but typically does not otherwise support the storage containers 106 when stacked. For example, as disclosed in NO317366, WO98 / 49075, and WO2015 / 019055, guiding vertical movement of the storage containers is obtained by having an upright member 102 featuring four corner sections, each corner section positioned to receive a corner of a storage container.

[0007] The automated storage and warehousing system 1 includes a rail system 108 arranged in a grid pattern across the top of the storage grid 104, and a plurality of container handling vehicles 200, 300 (as illustrated in FIGS. 1B and 1D ) are operated on the rail system 108 to raise storage containers 106 from, lower storage containers 106 into, and transport storage containers 106 up the storage columns 105. Of the grid cells 122 that make up the grid pattern, One of these horizontal extents is marked by a bold line in FIGS. 1A and 1C.

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

[0009] The rail system 108 comprises a first set of parallel rails 110 and a second set of parallel rails 111, the first set of parallel rails 110 arranged to guide the movement of the container handling vehicles 200, 300 in a first direction X across the top of the frame structure 100, and the second set of parallel rails 111 arranged perpendicular to the first set of rails 110 and guiding the movement of the container handling vehicles 200, 300 in a second direction Y perpendicular to the first direction X. The rail system 108 thus defines a grid column above which the container handling vehicles 200, 300 can move laterally above the storage columns 105, i.e. in a plane parallel to the horizontal XY plane.

[0010] Each prior art container handling vehicle 200, 300 includes a vehicle body and a wheel arrangement 201, 301 of eight wheels, with a first set of four wheels allowing lateral movement of the container handling vehicle 200, 300 in the X direction and the remaining four wheels in a second set allowing lateral movement in the Y direction. One or both sets of wheels in the wheel arrangement can be raised and lowered such that the first set of wheels and / or the second set of wheels can be engaged with the respective set of rails 110, 111 at any one time.

[0011] Each prior art container handling vehicle 200, 300 also includes a lifting device (not shown) for vertical transportation of the storage containers 106, e.g. for raising and lowering the storage containers 106 from and into the storage columns 105. The lifting device includes one or more gripping / engagement devices (not shown) adapted to engage the storage containers 106, such that the gripping / engagement devices can be lowered from the vehicle 201, 301 and that the position of the gripping / engagement devices relative to the vehicle 201, 301 can be adjusted in a third direction Z, the third direction Z being orthogonal to the first direction X and the second direction Y.

[0012] Conventionally, and for purposes of this application, Z=1 identifies the top layer of the grid 104, i.e., the layer immediately below the rail system 108, Z=2 identifies the second layer below the rail system 108, Z=3 identifies the third layer, and so on. In the exemplary prior art grid 104 disclosed in FIGS. 1A and 1C, Z=8 identifies the bottom layer at the bottom of the grid 104. Accordingly, by way of example and using the Cartesian coordinate system X, Y, Z shown in FIGS. 1A and 1D, a storage container identified as 106' in FIG. 1A may be said to occupy grid location or cell X=10, Y=2, Z=3. The container handling vehicle 101 may be said to travel in layer Z=0, and each grid column may be identified by its X and Y coordinates.

[0013] Each container handling vehicle 200 transports a storage container across the rail system 108. and a storage compartment or space (not shown) for receiving and storing storage container 106 when transporting 106. The storage space may include a cavity centrally located within the vehicle body, for example, as described in WO2014 / 090684A1, the contents of which are incorporated herein by reference.

[0014] Alternatively, the container handling vehicle 300 may have a cantilever beam construction as described in NO317366, the contents of which are also incorporated herein by reference.

[0015] The container handling vehicle 200 may have a predetermined footprint, i.e., extent in the X and Y directions, that is generally equal to the lateral extent of a grid cell 122, i.e., as described, for example, in WO2015 / 193278A1, the contents of which are incorporated herein by reference. As used herein, the term "lateral" may mean "horizontal."

[0016] Alternatively, the container handling vehicle 200 may have a footprint larger than the lateral extent of the grid columns (the lateral area defined by the grid columns), for example as disclosed in WO2014 / 090684A1.

[0017] The rail system 108 can be a single rail system, as shown in Figure 2A. Alternatively, the rail system 108 can be a double rail system, as shown in Figure 2B, thus allowing a container handling vehicle 201 having a footprint generally corresponding to the lateral area defined by the grid columns 112 (see Figure 2A) to travel along a row of grid columns (even when another container handling vehicle 200 is positioned above a neighboring grid column of the row). Both the single rail system and the double rail system, or a combination including the single rail arrangement and the double rail arrangement in the single rail system 108, form a grid pattern in the horizontal plane P including a plurality of rectangular and uniform grid locations or grid cells 122, where each grid cell 122 includes a grid opening 115 bounded by a pair of rails 110a, 110b of the first rail 110 and a pair of rails 111a, 111b of the second set of rails 111. In FIG. 2B, grid cell 122 is indicated by a dashed box.

[0018] Consequently, rails 110a and 110b form a rail pair that defines parallel rows of grid cells running in the X direction, and rails 111a and 111b form a rail pair that defines parallel rows of grid cells running in the Y direction.

[0019] As shown in FIG. 2C, each grid cell 122 has a width W that is typically spaced 30 cm to 150 cm apart. c , and a length L typically in the interval from 50 cm to 200 cm. c Each grid opening 115 has a grid cell 122 width W c and length L c Typically 2 to 10 cm smaller than the width W o and length L o It has.

[0020] In the X and Y directions, neighboring grid cells are placed in contact with each other such that there is no space between them.

[0021] Within the storage grid 104, the majority of the grid columns are storage columns 105. 1, i.e., the grid columns 105 in which the storage containers 106 are stored in stacks 107. However, the grid 104 typically has at least one grid column that is not used to store the storage containers 106, which at least one grid column includes a location where the container handling vehicles 200, 300 can drop and / or pick up the storage containers 106 so that the storage containers 106 can be transported to a second location (not shown) where they can be accessed from outside the grid 104 or transferred out of or into the grid 104. In the art, such locations are typically referred to as "ports" and the grid columns in which the ports are located can be referred to as "distribution columns" 119, 120. The drop and pick ports of the container handling vehicles are referred to as the "upper ports of the distribution column" 119, 120, while the opposite end of the distribution column is referred to as the "lower port of the distribution column."

[0022] The storage grid 104 in Figures 1A and 1C includes two delivery columns 119 and 120. The first delivery column 119 can include, for example, a dedicated drop port where the container handling vehicles 200, 300 can drop storage containers 106 for transport through the delivery column 119 and further to an access or transfer station, and the second delivery column 120 can include a dedicated pick port where the container handling vehicles 200, 300 can pick up storage containers 106 that have been transported from the access or transfer station through the delivery column 120. Each of the ports of the first and second delivery columns can include a port suitable for both picking up and dropping storage containers.

[0023] The second location can typically be a picking or stocking station where product items are removed from or positioned into the storage containers 106. At the picking or stocking station, the storage containers 106 are typically never removed from the automated storage system 1, but rather are accessed and placed back into the storage grid 104. There are also lower ports provided in the distribution column for the transfer of storage containers out of or into the storage grid 104, such as for transferring the storage containers 106 to another storage facility (e.g., to another storage grid), directly to a transport vehicle (e.g., a train or lorry), or to a production facility.

[0024] To monitor and control the automated warehouse system 1 (e.g., to monitor and control the location of each storage container 106 within the storage grid 104; the contents of each storage container 106; and the movements of the container handling vehicles 200, 300 so that the desired storage containers 106 may be delivered to the desired locations at the desired times without the container handling vehicles 200, 300 colliding with each other), the automated warehouse system 1 includes a control system (not shown), which is typically computerized and which typically includes a database for tracking the storage containers 106.

[0025] A conveyor system including a conveyor may be used to transport storage containers between a lower port of the distribution column and an access station (also referred to as a handling station or picking station).

[0026] If the lower ports and access stations of the distribution column are located at different levels, the conveyor system may include a lift device for transporting storage containers vertically between the ports and the access stations.

[0027] The conveyor system may be arranged to transport storage containers between different grids, for example as described in WO2014 / 075937A1, the contents of which are incorporated herein by reference.

[0028] Furthermore, WO2016 / 198467A1 (the contents of which are incorporated herein by reference) discloses examples of prior art access systems having conveyor belts (Figures 5a and 5b in WO2016 / 198467A1) and frame-mounted rails (Figures 6a and 6b in WO2016 / 198467A1) for transporting storage containers between a delivery column and a workstation where an operator can access the storage containers.

[0029] When a storage container 106 stored in the grid 104 disclosed in FIG. 1A is to be accessed, one of the container handling vehicles 200, 300 is commanded to retrieve the desired storage container 106 from its location in the grid 104 and transport the desired storage container 106 to or through a distribution column 119. This action involves moving the container handling vehicle 200, 300 to a location on the grid above the storage column 105 in which the desired storage container 106 is positioned, retrieving the storage container 106 from the storage column 105 using a lifting device (not shown) on the container handling vehicle, and transporting the storage container 106 to the distribution column 119. If the target storage container 106 is located deep in the stack 107, i.e., if one or more other storage containers remain positioned above the target storage container 106, the operation also involves temporarily moving the storage container positioned above before lifting the target storage container 106 from the storage column 105. This step, which may be referred to in the art as "digging", may be performed by the same container handling vehicle 200, 300 that is subsequently used to transport the target storage container 106 to the delivery column, or may be performed by one or more other cooperating container handling vehicles 200, 300. Alternatively or in addition, the automated warehouse system 1 may have container handling vehicles 200, 300 specifically dedicated to the task of temporarily removing the storage container 106 from the storage column 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container may be repositioned back into the original storage column 105. However, the removed storage container may alternatively be repositioned to another storage column 105.

[0030] When a storage container 106 is to be stored in the grid 104, one of the container handling vehicles 200, 300 is directed to pick up the storage container 106 from the delivery column 120 and transport the storage container 106 to a location on the grid above the storage column 105 where it is to be stored. After any storage containers positioned at or above the desired location in the storage column stack 107 have been removed, the container handling vehicles 200, 300 position the storage container 106 in the desired location. The removed storage container can then be lowered back into the storage column 105 or repositioned in another storage column 105.

[0031] A problem associated with known automated store-and-store systems 1 is that the areas surrounding the pick-up and drop-off ports can become congested with container handling vehicles 200, 300 being directed to drop-off or pick-up storage containers 106. This can seriously impede the operation of the automated store-and-store system 1. In smaller systems, this situation can potentially be alleviated by adding delivery columns to the grid, since this can reduce the number of delivery columns at the port to avoid congestion. This is because it allows container handling vehicles 200, 300 to be distributed between ports and columns. However, when ports and columns are added, the conveyor system infrastructure must usually be increased. This requires space, which may not always be available. Also, adding conveyor system infrastructure is costly.

[0032] Another problem with the prior art automated warehouse system 1 is that the separate drop and pick ports of the delivery columns 119, 120 require the container handling vehicles 200, 300 to travel to the storage column 105 after dropping off to pick up the new storage container 106. Similarly, the container handling vehicles 200, 300 must be free of storage containers 106 when they are sent to the pick port 120 to pick up the storage containers. This results in inefficiencies and causes increased congestion around the ports, because the container handling vehicles 200, 300 are moving around on the grid without their loaded storage containers 106. In addition, the delivery columns 119, 120 may take up space above the grid 104 that could be used for other purposes, such as the movement of the container handling vehicles 200, 300.

[0033] In view of the above, it would be desirable to provide an automated warehouse system, and a method for operating such a system, that solves or at least mitigates one or more of the above-mentioned problems associated with the use of prior art warehouse systems. Summary of the Invention [Problem to be solved by the invention]

[0034] It is an object of the present invention to provide an automated warehouse system that is more efficient than prior art systems by avoiding or at least reducing crowding of storage containers around a delivery column.

[0035] Another object is to provide an automated warehouse system which improves the availability of delivery columns for container handling vehicles operating on a rail system. [Means for solving the problem]

[0036] The invention is set out in the independent claims, with the dependent claims describing certain optional features of the invention.

[0037] The present invention relates to an automated warehouse system including an automated warehouse grid and a distribution system, the automated warehouse grid comprising: - a container handling vehicle rail system for guiding a plurality of container handling vehicles, the container handling vehicle rail system including a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane and extending in a first direction and the second set of parallel rails being disposed in the horizontal plane and extending in a second direction orthogonal to the first direction, the first and second sets of rails forming a grid pattern in the horizontal plane including a plurality of adjacent container handling vehicle grid cells, each container handling vehicle grid cell including a container handling vehicle grid opening, the container handling vehicle grid opening being defined by a pair of neighboring rails of the first set of rails and a pair of neighboring rails of the second set of rails, and the container handling vehicles are operable to retrieve storage containers from a stack of storage containers below the container handling rail system; a distribution column adapted to transport storage containers between a container handling vehicle and a distribution port located at a lower end of the distribution column; Including, The delivery system provides an automated warehouse system including a remotely operated delivery vehicle, the remotely operated delivery vehicle including a container carrier adapted to support a storage container, the delivery vehicle further adapted to transport the storage container between a first location represented by a delivery port and a second location, the second location including a robotic operator for handling product items in the storage container.

[0038] The automated warehouse system may further include a delivery rail system including a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane P1 and extending in a first direction X, and the second set of parallel rails being disposed in the horizontal plane P1 and extending in a second direction Y orthogonal to the first direction X, the delivery rail system extending from a location below the delivery port to a second location. A delivery vehicle may be configured to travel over the delivery rail system between the location below the delivery port and the second location.

[0039] The delivery rail system will typically be located at ground floor level, thereby allowing easy access to the storage containers for the robotic operator (and in one embodiment, for humans as well). However, the delivery rail system may be located at any level below the upper level of the storage grid. In a preferred configuration, the entire delivery rail system is located at a level below the pick-up and / or drop-off ports of the storage grid.

[0040] In one embodiment of the storage system, the delivery rail system includes or is defined by a plurality of horizontal ceiling profiles, vertical support profiles disposed at both ends of at least some of the ceiling profiles (e.g., at both ends of at least some of the ceiling profiles and the delivery system), or sections of the delivery rail system disposed within the storage grid. The ceiling profiles and support profiles may also be referred to as ceiling beams and support beams.

[0041] In one embodiment of the storage system, a plurality of horizontal ceiling profiles provide or are arranged as a horizontal support grid, the horizontal support grid defining a plurality of support grid cells, at least some of which may be transfer ports through which storage containers may be transferred.

[0042] In one embodiment of the storage system, at least some of the plurality of horizontal ceiling profiles may be narrower than the uprights.

[0043] In one embodiment of the storage system, each of the upright members includes four corner sections, each positioned to receive a corner of the storage container.

[0044] In one embodiment of the storage system, each of the plurality of distribution columns includes a distribution port at their lower end. The distribution ports may be located at a level above the distribution rail system, allowing a distribution vehicle to be positioned directly below the transfer port to receive or distribute storage containers.

[0045] The delivery system may include interfaces that allow connection to third party storage, production, and distribution systems.

[0046] The delivery system should be capable of being integrated with third-party storage, production and distribution systems. Possibly, storage containers may be transported between the distribution system and third party storage, production, and distribution systems.

[0047] The distribution system of the present invention may be connectable to third party storage, production, and distribution systems, such as production facilities, storage grids, assembly facilities, receiving or shipping locations, etc. The connection can be by a connectable rail system or by a conveyor system, including conveyors used to transport storage containers between the distribution system and the third party storage, production, and distribution systems.

[0048] The delivery vehicle can include a weighing mechanism, such as a commercially available electronic weighing scale, to measure the weight of the storage containers. Such a weighing mechanism can provide information about the inner contents of each storage container, such as total weight, number of units, internal weight distribution, and / or the location within the storage grid where the storage container should be placed.

[0049] Preferably, at least one distribution column is positioned such that a container handling vehicle can lower a storage container from the upper rail grid, through the distribution column, and into a distribution vehicle positioned below the distribution column. Consequently, the lower end of the distribution column has an opening (i.e., a transfer port) to allow the storage container to enter the distribution rail system from above.

[0050] To maximize storage space for storage containers in the warehouse grid, it may be advantageous to arrange the distribution rail system so that it extends as little as possible into the storage grid, which means that the warehouse grid can include multiple storage columns extending from an upper level to the base of the storage grid, thus allowing the maximum possible storage capacity, because the entire storage column can be used for storage.

[0051] In order to maintain the maximum possible storage capacity, the portion of the distribution rail system that extends into the storage grid may be kept as small (to a small extent) as possible, so that the distribution rail system and distribution vehicles can occupy as little space as possible of the warehouse grid, which space can be used for storage of storage containers.

[0052] The delivery rail system can include a first rail system positioned within the framework structure of the storage grid and a second rail system positioned outside the framework structure of the storage grid, the first and second rail systems connected such that a delivery vehicle can operate between the rail systems.

[0053] The second location may be connected to a second rail system.

[0054] The automated warehouse system may further include a gantry arrangement above the delivery vehicle, and the robotic operator may be in the form of at least one robotic arm suspended from the gantry arrangement. The robotic operator suspended from the gantry arrangement may be any suitable device for picking product items from storage containers.

[0055] Alternatively or additionally, floor-based, base-mounted and / or delivery rail-mounted robotic arms may be used in combination with the gantry structure suspended robotic arms.

[0056] The gantry arrangement can span at least a portion of the delivery rail system, and at least one robotic arm can be configured to move in XYZ directions (e.g., to move in all directions) to access storage containers at different locations in the delivery / delivery rail system. Regardless of whether the robot operator is configured to navigate itself, it can still be operable to pick and place product items from storage containers at multiple locations in the delivery system.

[0057] At least a portion of the gantry arrangement may be laterally offset from the delivery rail system, and the at least one robotic arm may be configured to travel laterally along the gantry arrangement to insert product items into or remove product items from a third location outside the delivery rail system.

[0058] At least a portion of the gantry arrangement may be laterally offset from the delivery rail system, and the at least one robotic arm may be configured to deliver at least one product item to or retrieve at least one product item from a third location outside of the delivery rail system by varying a range of robotic arm lengths.

[0059] Therefore, as an alternative to lateral progression, a robotic arm or robotic operator with sufficient reach may be provided to move the product items.

[0060] The third location can be a temporary location for storing a plurality of product items, and the at least one robotic arm can be configured to deliver the at least one product item to the temporary location.

[0061] The third location can be a shipping container for storing one or more product items, and the robotic arm can deliver at least one product item to the shipping container for further shipping.

[0062] The third location may be a temporary location for storing multiple product items.

[0063] The robot operator can be in the form of at least one robotic arm supported on a floor base, on a base above the delivery rail system, or on the delivery rail system.

[0064] At least one robotic arm may be gantry mounted or supported either on a floor base, on a base above the delivery rail system, or on the delivery rail system, and may be configured to be moved in X, Y, and Z directions to access storage containers at different locations in the delivery rail system and to transfer at least one product item between storage containers in the delivery rail system and / or to item carriers on an aggregation vehicle and / or into a third location outside the delivery rail system. The third location may be any of the third locations described above.

[0065] The present invention relates to a method of transporting storage containers between an automated warehouse grid and a second location for handling product items in the storage containers by a robotic operator, the automated warehouse grid comprising: - a container handling vehicle rail system for guiding a plurality of container handling vehicles, the container handling vehicle rail system including a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane and extending in a first direction and the second set of parallel rails being disposed in the horizontal plane and extending in a second direction orthogonal to the first direction, the first and second sets of rails forming a grid pattern in the horizontal plane including a plurality of adjacent container handling vehicle grid cells, each container handling vehicle grid cell including a container handling vehicle grid opening, the container handling vehicle grid opening being defined by a pair of neighboring rails of the first set of rails and a pair of neighboring rails of the second set of rails, and the container handling vehicles are operable to retrieve storage containers from a stack of storage containers below the container handling rail system; a distribution column adapted to transport storage containers between a container handling vehicle and a distribution port located at a lower end of the distribution column; Including, The method is: - lowering the storage container through at least one shipping column to a first location represented by a shipping port; - positioning a remotely operated delivery vehicle beneath the delivery port and receiving the storage container onto a container carrier provided on the remotely operated delivery vehicle; - transporting the storage container to a second location using a remote-operated delivery vehicle; - using at least one robotic operator to pick at least one product item from a storage container at a second location; The present invention further provides a method comprising:

[0066] The method is: - operating the remotely operated delivery vehicle back to the delivery port, which includes operating a rolling device of the remotely operated delivery vehicle; - lifting the storage container from the delivery vehicle through at least one delivery column for storage of the storage container in the automated warehouse grid; The delivery column through which the storage container is returned to the warehouse grid may be the same delivery column through which it was previously dispensed, or may be a separate delivery column (e.g., that is used only for storage containers returning to the warehouse grid).

[0067] The method is: - utilising a robotic operator in the form of at least one robotic arm suspended from a gantry arrangement above the delivery vehicle.

[0068] The gantry structure can span at least a portion of a delivery rail system, the delivery vehicle operating over the delivery rail system, and the method can include: - Operate at least one robotic arm to move in XYZ directions, thereby enabling access to storage containers at different locations in the delivery rail system.

[0069] At least a portion of the gantry arrangement can be laterally offset from the delivery rail system, and the method includes: - It may further include a step of operating at least one robotic arm to advance laterally along the gantry arrangement for inserting or retrieving a product item into or from a third location outside the delivery rail system.

[0070] The method is: - utilizing a robot operator in the form of at least one robotic arm, the at least one robotic arm being supported on a floor base, on a base above a delivery rail system on which the delivery vehicle operates, or on the delivery rail system on which the delivery vehicle operates.

[0071] The method is: - moving at least one robotic arm in XYZ directions to access storage containers at different locations within the delivery rail system, and transferring at least one product item between the storage container in the delivery rail system and a third location outside the delivery rail system.

[0072] The third location may be a shipping container for storing one or more product items, and the method may include operating the at least one robotic arm to deliver the at least one product item to the shipping container for further shipping.

[0073] The present invention relates to a method of transferring at least one product item between an automated warehouse grid and a second location, the automated warehouse grid comprising: - a container handling vehicle rail system for guiding a plurality of container handling vehicles, the container handling vehicle rail system including a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane and extending in a first direction and the second set of parallel rails being disposed in the horizontal plane and extending in a second direction orthogonal to the first direction, the first and second sets of rails forming a grid pattern in the horizontal plane including a plurality of adjacent container handling vehicle grid cells, each container handling vehicle grid cell including a container handling vehicle grid opening, the container handling vehicle grid opening being defined by a pair of neighboring rails of the first set of rails and a pair of neighboring rails of the second set of rails, and the container handling vehicles are operable to retrieve storage containers from a stack of storage containers below the container handling rail system; a distribution column adapted to transport storage containers between a container handling vehicle and a distribution port located at a lower end of the distribution column; Including, The method is: - positioning a remotely operated delivery vehicle with the storage container to be filled at a second location; - using at least one robotic operator to place at least one product item into a storage container; - using a remote-operated delivery vehicle to bring the storage container down to the delivery port; - operating a container handling vehicle to retrieve storage containers from the remotely operated delivery vehicle through at least one delivery column; The present invention further provides a method comprising:

[0074] The remotely operated delivery vehicle can operate the rolling device to bring the storage container below the delivery port.

[0075] The system may include a plurality of stacks of storage containers disposed in storage columns positioned below the rail system, each storage column positioned vertically below a grid opening, and the system includes: - including a plurality of container handling vehicles for lifting and moving storage containers stacked in a stack, each container handling vehicle configured to travel on the rail system above the storage column.

[0076] The delivery rail system can include a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane and extending in a first direction, and the second set of parallel rails being disposed in the horizontal plane and extending in a second direction orthogonal to the first direction.

[0077] Each robot operator according to the present invention can reach multiple locations in the distribution system. This fact, i.e., that the robot operators can access multiple locations in the distribution system, completely eliminates or at least minimizes the need for access ports with prior art solutions. Robot operators (e.g., either gantry-mounted or base-mounted on or next to the distribution rail system) can move to access storage containers transported on remotely operated delivery vehicles at different locations in the distribution system. For example, in known conveyor systems, storage containers are only accessible by any given robot at one point on the conveyor.

[0078] The third location can be at a robot operator, e.g., in a system where more than one robot operator is used, one or more of the robot operators can serve as a temporary storage location for the product item, e.g., until other product items to be sent to the same client are picked up.

[0079] The disclosed system and method may have additional advantages over the prior art in that conventional conveyor systems are not only expensive but also represent a single point of failure. Remotely operated delivery vehicles may avoid obstacles (e.g., a robot operator waiting for a container or a faulty robot operator) by changing their routes, or, in the case of a faulty delivery vehicle in the delivery system, a robot operator may access product items in a storage container being transported by the faulty delivery vehicle. The latter is made possible because the entire delivery rail system may act as a conventional port, provided that at least one of the robot operators is able to access any position in the delivery rail system. Thus, unforeseen problems that may occur in a conventional port are avoided.

[0080] Delivery vehicles can function in a manner similar to the Internet, transporting their packages between "nodes" along routes that can be changed as needed without colliding with one another due to the double-track rail layout and single grid cell size of the delivery rails, all the while being accessible by robotic operators.

[0081] Moreover, different parts of the delivery rail system may be assigned to storage containers with different types of product items (e.g., refrigerated, shelf-stable, fresh, etc.), such that different robot operators (or a common robot operator) may be assigned to different parts of the delivery rail system.

[0082] The robot operator can select different types of product items depending on the product item. For example, a storage container with refrigerated items can be assigned to a part of a delivery rail system with refrigeration, and the robot operator can be instructed to pick the refrigerated item near the completion of a particular order. In contrast, a storage container with a product item that is not temperature sensitive can be picked as one of the first items in a particular order.

[0083] According to further aspects of the invention, or in addition to the foregoing, the robot operator may be configured to rearrange or reposition product items in storage containers and / or to move product items between storage containers (e.g., storage containers being carried by a delivery vehicle as described herein). The robot operator may be configured to transfer product items between storage containers being carried by a delivery vehicle prior to storage of at least one of the storage containers and / or before at least one of the storage containers is presented for picking of product items therein. Thus, the robot operator may be configured to organize product items in a warehouse system and / or may be used to refine the contents of a storage container, for example, before the storage container is presented for selection of product items therein, such as for delivery. This may be advantageous, for example, when one storage container is nearly empty and the remaining items are moved to another storage container with the same product items.

[0084] Such transfer may be performed by a robotic arm capable of picking the product item from a storage container in a first remotely operated delivery vehicle, a second remotely operated delivery vehicle with a storage container capable of replacing the first remotely operated delivery vehicle, and the arm capable of placing the product item in the storage container in the second remotely operated delivery vehicle. Also, the robotic arm may transfer the product item between neighboring or nearby delivery vehicles or storage containers, for example, without the delivery vehicle moving during the transfer.

[0085] Additionally or alternatively, the robot operator can move all product items from one container into another, for example combining partially empty storage containers to create a full container and a spare empty container. Conversely, the robot operator can distribute the product items evenly from the container, ensuring that multiple storage containers have the required product items and improving access efficiency for that product item type. In this latter solution, the second and / or third locations can be storage containers on another remote-operated delivery vehicle. The second and / or third locations can be referred to as item picking areas in this setup.

[0086] Additionally, the robotic operator can move product items from one or more storage containers into item carriers on the aggregation vehicle to complete or partially complete the product order at a handling or picking station or prior to presentation to an item aggregation area.

[0087] The aggregation vehicle (the robot operator) places the products into the item carrier on the aggregation vehicle. The aggregation vehicle may be movable in both X and Y directions on the delivery rail system (including a location on the delivery rail system where an item can be placed or picked up from an item carrier on the aggregation vehicle). Such a location on the delivery rail system may be referred to as an item picking area. The item carrier may include four side walls, a bottom section, and an open top, and one of the side walls or bottom section may be openable so that the product items may be removed from the item carrier in a horizontal or vertical direction, respectively. When the aggregation vehicle is transported to the item aggregation area (which is an area where the aggregation vehicle may be positioned to deliver the product items stored in the item carrier), it may be removed to a packaging / processing assembly where the product order is finalized and prepared for shipment.

[0088] In an embodiment, one of the sidewalls or bottom sections of the aggregation vehicle may be connected to an actuator such that the sidewall or bottom section may be opened or closed by activating the actuator. In other words, the openable sidewall or bottom section provides an opening in the item carrier when the openable sidewall or bottom section is in an open position. Alternatively, one of the sidewall or bottom section is comprised of or includes at least one actuating surface.

[0089] Moreover, the robot operator can also be used as part of the process of rearranging the product items in the storage container before the storage container with the product items is presented to the operator at the picking station. The product items in the storage container may have been picked by the robot operator or the storage container can come directly from a stack of storage containers under the container handling vehicle rail system. The operator at the picking station can then only need to check the storage container contents before the storage container is prepared for further transportation or shipping. If the product items are randomly arranged in the storage container, the robot operator can be utilized to systematize or rearrange the product items at an intermediate pre-picking stage so that when the storage container arrives at the picking station, the product items are automatically arranged and all of the product items are visible from above by a human operator or a camera (the operator can then be in another location and simply check the contents in the storage container by controlling a snapshot taken by the camera of the product items in the storage container).

[0090] Such a method may include a step of picking at least one product item from the storage container by a robotic operator after the storage container is transported to a second location by a delivery vehicle, and automatically placing the picked product item into the same storage container, e.g., to reorder the product items in the storage container.

[0091] Moreover, the robot operator may also be used as part of a process to rearrange different categories of product items stored in one common storage container into multiple other storage containers (e.g., one storage container for each different product category). For example, one storage container may contain various medications from one medication provider and may be stored in the automated warehouse grid. The automated warehouse system may then bring this storage container with the different medications to a robot operator at a second location whenever it has the time and capacity, such that the robot operator can place one type of medication in each storage container.

[0092] Such a method may include, after the storage container is transported to the second location by a delivery vehicle, - picking at least one product item from a storage container by a robotic operator and placing the picked product item in another respective storage container.

[0093] 1. A method of aggregating a plurality of items in an automated warehouse grid and a second location, the automated warehouse grid comprising: - a container handling vehicle rail system for guiding a plurality of container handling vehicles, the container handling vehicle rail system including a first set of parallel rails and a second set of parallel rails, the first set of parallel rails being disposed in a horizontal plane and extending in a first direction and the second set of parallel rails being disposed in the horizontal plane and extending in a second direction orthogonal to the first direction, the first and second sets of rails forming a grid pattern in the horizontal plane including a plurality of adjacent container handling vehicle grid cells, each container handling vehicle grid cell including a container handling vehicle grid opening, the container handling vehicle grid opening being defined by a pair of neighboring rails of the first set of rails and a pair of neighboring rails of the second set of rails, and the container handling vehicles are operable to retrieve storage containers from a stack of storage containers below the container handling rail system; a distribution column adapted to transport storage containers between a container handling vehicle and a distribution port located at a lower end of the distribution column; Including, The method is: - positioning a remotely operated delivery vehicle with a first storage container at a second location; - positioning the aggregation vehicle with the item carriers at a second location; - using at least one robotic operator to transfer at least one product item from a storage container carried by the remote-operated delivery vehicle into an item carrier; - transferring a second product item from the first storage container or from a second storage container carried by another remotely operated delivery vehicle into an item carrier of the aggregation vehicle by using the robotic operator; - moving the aggregated vehicles to an aggregation area on a distribution rail system of a transfer rail grid; - opening an openable side wall or bottom section of the aggregation vehicle so that the first and second items may be removed from the item carrier in a horizontal or vertical direction. A method is further described, including:

[0094] The following drawings illustrate alternative embodiments of the present invention and are included to facilitate an understanding of the present invention. However, the features disclosed in the drawings are for illustrative purposes only and should not be construed in a limiting sense. [Brief description of the drawings]

[0095] [Figure 1A] FIG. 1 is a perspective view of a prior art automated storage system showing the complete system. [Figure 1B] FIG. 1 is a perspective view of a prior art automated warehouse system, showing an example of a prior art container handling vehicle capable of operating with the system. [Figure 1C] FIG. 1 is a perspective view of a prior art automated storage system showing the complete system. [Figure 1D] FIG. 1 is a perspective view of a prior art automated warehouse system, showing an example of a prior art container handling vehicle capable of operating with the system. [Figure 2A] FIG. 1 is a top view of a container handling vehicle rail system showing a single track system. [Figure 2B] FIG. 1 is a top view of the container handling vehicle rail system showing a double track system. [Figure 2C] FIG. 1 is a top view of the container handling vehicle rail system showing the width and length shown in a double track system of container handling vehicle grid cells. [Figure 3A] FIG. 2 is a side view of a remote-controlled delivery vehicle. [Figure 3B] FIG. 1 is a perspective view of a remote-operated delivery vehicle having a container carrier with a compartment for holding storage containers. [Figure 3C]FIG. 1 is a perspective view of a remote-operated delivery vehicle having a conveyorized container carrier. [Figure 3D] FIG. 1 is a perspective view of a remote-controlled delivery vehicle in which a container carrier can be set in an inclined position relative to the vehicle body. [Figure 4A] FIG. 1 is a perspective view of an automated warehouse grid and distribution system (robot operators not shown). [Figure 4B] FIG. 1 is a perspective view of an automated warehouse grid and distribution system (robot operators not shown). [Figure 4C] FIG. 1 is a side view of an automated warehouse system including an automated warehouse grid and a distribution system (robot operators not shown). [Diagram 5] FIG. 1 is a perspective view of an automated warehouse system including an automated warehouse grid and a distribution system with two robotic operators in the form of two robotic arms supported above a floor base at the distribution system for picking and placing items into storage containers. [Figure 6A] FIG. 1 illustrates two different perspective views of an automated warehouse system including an automated warehouse grid and a distribution system, with a gantry arrangement above a portion of the distribution system and a robot operator in the form of at least one robotic arm suspended from the gantry arrangement; [Figure 6B] FIG. 1 illustrates two different perspective views of an automated warehouse system including an automated warehouse grid and a distribution system, with a gantry arrangement above a portion of the distribution system and a robot operator in the form of at least one robotic arm suspended from the gantry arrangement; [Figure 6C] FIG. 6C is an alternative to the system disclosed in FIGS. 6A and 6B, showing a larger system with four delivery rail systems and four gantry structures, one structure above each of the four delivery rail systems. [Figure 7A]FIG. 1 is a different perspective view of an automated warehouse system including an automated warehouse grid and a distribution system, a common distribution rail system and four robot operators at different locations outside the distribution rail system, the robot operators being in the form of at least one robot arm supported above a floor base at the distribution system for picking and placing items between storage containers and shipping containers on a conveyor belt. [Figure 7B] FIG. 1 is a different perspective view of an automated warehouse system including an automated warehouse grid and a distribution system, a common distribution rail system and four robot operators at different locations outside the distribution rail system, the robot operators being in the form of at least one robot arm supported above a floor base at the distribution system for picking and placing items between storage containers and shipping containers on a conveyor belt. [Figure 8A] FIG. 2 is a different perspective view of an automated warehouse system including an automated warehouse grid and a distribution system, with a common distribution rail system, with a common gantry arrangement spanning a portion of the distribution rail system and with a number of robot operators in the form of robotic arms suspended from the gantry arrangement; [Figure 8B] FIG. 2 is a different perspective view of an automated warehouse system including an automated warehouse grid and a distribution system, with a common distribution rail system, with a common gantry arrangement spanning a portion of the distribution rail system and with a number of robot operators in the form of robotic arms suspended from the gantry arrangement; [Figure 9A] FIG. 1 illustrates an example of a distribution rail system positioned adjacent to a rail system on which container handling vehicles operate, with two gantry structures with suspended robotic operators positioned in the transition zone between the two rail systems, and the distribution rail system including an item aggregation area for receiving picked product items for further transport. [Figure 9B]FIG. 9B is a detailed view of the item aggregation area of ​​FIG. 9A, which is disclosed as including five conveyors and multiple horizontal openings for receiving and further transporting the picked product items. [Figure 9C] FIG. 1 is a side view of an aggregation vehicle operable on a distribution rail system, the aggregation vehicle being disclosed as having an openable sidewall for passing product items from the aggregation vehicle's item carriers and into a horizontal opening in the distribution rail system for further transportation. [Figure 10A] FIG. 1 discloses an aggregation vehicle with an actuator for closing an openable side wall of the aggregation vehicle so that product items can be removed from the item carriers of the aggregation vehicle. [Figure 10B] FIG. 1 discloses an aggregation vehicle with an actuator for opening an openable side wall of the aggregation vehicle so that product items can be removed from the item carriers of the aggregation vehicle. [Figure 10C] FIG. 10 discloses an aggregation vehicle with an openable bottom section, allowing product items in item carriers in the aggregation vehicle to fall by gravity, possibly through an underlying horizontal opening, to a lower level of the aggregation vehicle for further transport. [Figure 10D] FIG. 10 discloses an aggregation vehicle with an openable bottom section, allowing product items in item carriers in the aggregation vehicle to fall by gravity, possibly through an underlying horizontal opening, to a lower level of the aggregation vehicle for further transport. [Figure 10E]FIG. 1 discloses (starting from the left to the right in the figure) a distribution rail system with handling or picking stations; an item picking area with robotic operators for moving product items between storage containers carried by the distribution vehicles; and an item picking area with robotic operators for moving product items from the storage containers to item carriers on an aggregation vehicle. [Figure 10F] FIG. 10F shows a detail of an item picking area with a robotic operator for moving product items from storage containers to item carriers of the aggregation vehicle of FIG. 10E. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0096] In the following, different alternatives will be discussed in more detail with reference to the attached drawings. However, it should be understood that the drawings are not intended to limit the scope of the invention to the subject matter shown therein. Moreover, even if some of the features are described only in relation to a system, it is clear that they are equally valid for the method and vice versa.

[0097] 1A to 1D, the storage grids 104 of each storage structure 1 include a total of constitute a framework 100 of 143 grid columns 112 (see the grid column 112 in the top front corner, i.e., grid location or cell X=11, Y=1, Z=0), with the width and length of the framework corresponding to the width and length of 13 and 11 grid columns 112, respectively. The upper layer of the framework 100 is a container handling vehicle rail system / rail system 108 upon which a plurality of container handling vehicles 200, 300 are operated.

[0098] The framework 100 of the storage system 1 is constructed according to the above-mentioned prior art framework 100 described above, i.e. according to a number of upright members 102 and a number of horizontal members 103 supported by the upright members 102, further according to which the horizontal members 103 include a container handling vehicle rail system 108 of parallel rails 110, 111 in the X and Y directions, respectively, arranged across the top of the storage columns 105. The horizontal area of ​​a single grid cell 122, i.e. the area along the X and Y directions, respectively, can be defined by the distance between adjacent rails 110 and 111 (see also Figures 2A-2C). In Figures 1A and 1C, such a grid cell 122 is marked above the rail system 108 by a bold line. To guide vertical movement of the storage container, each of the uprights 102 has a cross-section featuring four corner sections, each positioned to receive a corner of the storage container 106.

[0099] The container handling vehicle rail system 108 allows the container handling vehicles 200 , 300 to move horizontally between different grid locations, each of which is associated with a grid cell 122 .

[0100] In Figures 1A and 1C, the storage grid 104 is shown with a height of eight cells. However, it is understood that the storage grid 104 can, in principle, be of any size. In particular, it is understood that the storage grid 104 can be significantly wider and / or longer than that disclosed in Figures 1A and 1C. For example, the grid 104 can have a horizontal extent of more than 700x700 grid cells 122, or any size between these examples, for example, 100x100 grid cells, 200x200 grid cells, 500x500 grid cells, etc. Also, the grid 104 can be significantly deeper than that disclosed in Figures 1A and 1C. For example, the storage grid 104 can be greater than 12 grid cells deep.

[0101] The storage container vehicles 200, 300 may be of any type known in the art, for example any one of the automated container handling vehicles disclosed in WO2014 / 090684A1, NO317366 or WO2015 / 193278A1.

[0102] The rail system 108 can be a single rail system, as shown in Figure 2A. Alternatively, the rail system 108 can be a double rail system, as shown in Figure 2B. Details of single and double rail systems are disclosed herein under the Background and Prior Art sections.

[0103] FIG. 3A shows a remotely operated delivery vehicle 30 (hereafter referred to as delivery vehicle 30). (I).

[0104] The delivery vehicle 30 is configured for transport of one or more storage containers 106 (not shown) between an automated storage grid 104 (not shown) configured to store a plurality of stacks 107 of the storage containers 106 (hereafter referred to as the storage grid 104) and a second location. The second location includes a robotic operator 160 for handling items in the storage containers 106. There may be several robotic operators, or there may be a robotic operator in combination with one or more human operators 164 (see, for example, FIGS. 6A-6C). The delivery vehicle 30 may be configured for transport of only one storage container 106, or may be configured for transport of two or more storage containers at the same time.

[0105] 3A-3D, the delivery vehicle 30 includes a vehicle body 31, a rolling device 32 connected to the vehicle body 31, a rolling device motor (not shown) for driving the rolling device 32 in a horizontal plane P1, and a power source (not shown) connected to the rolling device motor. The power source should provide sufficient power to the rolling device motor to propel the rolling device 32 over a set route from the storage grid 104 to, for example, a second location.

[0106] The delivery vehicle 30 may further include a container carrier 35 mounted above the vehicle body 31. The container carrier 35 should be configured to receive the storage container 106 on or within the container carrier 35 such that the storage container 106 is restrained from moving horizontally relative to the container carrier.

[0107] The container carrier 35 may include a container support device that supports the storage container 106 from below.

[0108] In Fig. 3A, the container carrier 35 is disclosed in the form of a storage container receiving compartment having a bottom / base and sidewalls. The compartment volume is such that in this exemplary configuration, it is capable of receiving and containing the entire horizontal extent of the storage container and at least a portion of the vertical extent of the storage container. Figs. 3A and 3B show an example of a container carrier 35 containing an entire storage container 106, Fig. 3B shows an alternative container carrier 35 containing a portion of the storage container 106, while Fig. 3C shows another alternative, where the delivery vehicle 30 has a container carrier 35 provided with a conveyor 36.

[0109] The particular configuration of the container carrier 35 disclosed in FIG. 3A allows the delivery vehicle 30 to transport storage containers 106 having different heights.

[0110] It should be noted that the size of the compartments within the container carrier 35 can be easily adapted to receive and support multiple storage containers 106 in one operation.

[0111] 3D shows an alternative configuration of the delivery vehicle 30, in which the container carrier 35 can be moved to a position tilted with respect to the vehicle body 31 and the horizontal plane P1. The container carrier 35 can be tilted by a dedicated displacement device (e.g. tilt motor 41). The tilting can be performed around a pivot axis oriented in the main directions of movement of the delivery vehicle 30. In case the delivery vehicle 30 travels on vertical rails (see below), these main directions will be in either the X-direction or the Y-direction.

[0112] Tilting of the displacement device can be obtained, for example, by a lifting arm 45 connected to the vehicle body 31 and the container carrier 35. Furthermore, the lifting arm 45 can be driven by a dedicated tilt motor (not shown) or a rolling device motor, or both.

[0113] When used on a delivery rail system 50 (see Figures 4A, 4B, 4C, 5, 6A-6C, 7A-7B, 8A-8B), one of both sets of wheels 32a, 32b of the rolling device 32 should be raised and lowered so that the first set of wheels 32a and / or the second set of wheels 32b can be engaged with the respective set of rails provided on the delivery rail system 50 at any one time.

[0114] 3B illustrates another alternative embodiment of a remotely operated delivery vehicle 30. Similar to the container carrier 35 described above, the container carrier 35 in this configuration is a container support device for supporting a storage container 106 from below.

[0115] Thus, the container support device includes a base plate, which is provided with side walls along its periphery or perimeter, thereby defining a compartment. The horizontal extent of the compartment is adapted to be large enough to receive one or more storage containers 106 and small enough to substantially prevent movement of the one or more storage containers 106 when inserted. However, in contrast to the exemplary configuration of the delivery vehicle 30 shown in FIG. 3A, the one or more side walls of the container support device in FIG. 3B have a vertical height that is smaller than the vertical height of the respective storage container 106. In fact, to achieve the purpose of the side walls of the container carrier 35 (to substantially prevent horizontal movement when inserted), it is sufficient to have only a small vertical protrusion upwards from the base plate, for example less than 5% of the height of the side walls of the storage containers 106.

[0116] 3C illustrates yet another exemplary configuration of a remotely operated delivery vehicle 30. In this configuration, a container carrier 35 includes a base plate, a conveyor 36 with rollers disposed on the base plate, and two parallel side walls projecting upwardly from the base plate. The rolling device 32 and vehicle body 31 are the same as or similar to the rolling device 32 and vehicle body 31 described above in connection with FIGS. 3A and 3B.

[0117] The conveyor 36 may be configured with a number of parallel oriented rollers having a common longitudinal direction perpendicular to the two side walls. In this way, the rollers allow one or more storage containers 106 to be shifted into or out of the container carrier 35 while being guided by the side walls. The conveyor may be connected to a conveyor motor (not shown) that drives the rotation of one or more of the rollers.

[0118] Alternatively, the side walls are omitted, allowing the storage container 106 to have a horizontal offset relative to a vertical center plane that is oriented perpendicular to the length of the roller. Thus, the storage container 106 may be positioned such that it extends beyond the ends of the roller in the length of the roller.

[0119] In yet another alternative configuration, the conveyor may include multiple rolling balls in or on the base plate of the container carrier 35, and may be configured to roll one or more storage containers. This allows the container 106 to roll on the ball. With this configuration, and the absence of side walls, the storage container 106 can be moved in any direction above the base plate.

[0120] 4A, 4B, and 4C are perspective views of an automated warehouse system without a robotic operator. The system includes a storage grid 104 and a distribution system 140 including the delivery vehicles 30 described above. The distribution system 140 defines a plurality of grid cell distribution rail systems 122' (see FIG. 9B), at least some of which are distribution ports 119, 120 through which the storage containers 106 may be transported.

[0121] The storage grid 104 is the same as or similar to the prior art storage grid 104 described above with respect to Figures 1A-1C, i.e., a storage grid 104 including a rail system 108, multiple stacks 107 of storage containers 106, multiple container handling vehicles 300 for lifting and moving the storage containers 106 stacked in the stacks 107 (not shown in Figures 4A and 4B), and delivery columns 119, 120 configured to receive the storage containers 106 from the container handling vehicles 200, 300.

[0122] The rail system 108 includes a first set of parallel rails 110 and a second set of parallel rails 111, the first set of parallel rails 110 being disposed in a horizontal plane P and extending in a first direction X, and the second set of parallel rails 111 being disposed in the horizontal plane P and extending in a second direction Y perpendicular to the first direction X. The first and second sets of rails 110, 111 form a grid pattern in the horizontal plane P that includes a plurality of adjacent grid cells 122. Each grid cell 122 includes a grid opening that is defined by a pair of neighboring rails of the first set of rails 110 and a pair of neighboring rails of the second set of rails 111.

[0123] A number of stacks 107 are arranged in storage columns 105 positioned below a rail system 108 , with each storage column 105 positioned vertically below a grid cell 122 .

[0124] Each container handling vehicle 200 , 300 is configured to travel on a rail system 108 above the storage columns 105 .

[0125] Additionally, the distribution system 140 includes one or more of the distribution vehicles 30 as described above, i.e., a distribution vehicle 30 configured to receive and support one or more storage containers 106 for transport between one or more distribution columns 119, 120 and one or more predetermined locations outside the storage grid 104. The predetermined location can be, for example, a second location, or a conveyor line, or a transport vehicle, e.g., a truck, etc.

[0126] The delivery system 140 may further include a delivery rail system 50 located below delivery ports 150 of one or more of the delivery columns 119, 120.

[0127] As shown in FIGS. 4A-4B, the distribution rail system 50 may be constructed in the same or similar manner as the rail system 108 for the container handling vehicles 200, 300.

[0128] Thus, the delivery rail system 50 may include a first set of parallel rails 51 and a second set of parallel rails 52, the first set of parallel rails 51 being arranged in a horizontal plane P1 and extending in a first direction X, and the second set of parallel rails 52 being arranged in the horizontal plane P1 and extending in a second direction Y perpendicular to the first direction X.

[0129] The delivery rail system 50 may also be a double rail system, as shown in FIG. 2B, thus allowing a remotely operated delivery vehicle 30 having a footprint generally corresponding to the lateral area defined by the delivery grid column to travel along a row of grid columns (even when another delivery vehicle 30 is positioned above a neighboring grid column of that row).

[0130] Both the single rail system and the double rail system, or a combination including single rail and double rail configurations in the single rail system, form a grid pattern or grid cells in the horizontal plane P1 including a plurality of rectangular and uniform grid locations, where each grid cell includes a grid opening bounded by a pair of rails of the first set of rails and a pair of rails of the second set of rails.

[0131] Pairs of rails in the X direction define parallel rows of distribution grid cells that run in the X direction, and pairs of rails in the Y direction define parallel rows of distribution grid cells that run in the Y direction.

[0132] Thus, each distribution grid cell has a width W that is typically spaced 30 cm to 150 cm apart. c , and a length L typically in the interval from 50 cm to 200 cm. c Each grid opening 115 has a width W of a distribution grid cell. c and length L c Typically 2 to 10 cm smaller than the width W o and length L o It has.

[0133] The delivery rail system 50 may be fully or partially integrated into the storage grid 104. However, it is believed to be advantageous to ensure effective operation for the delivery rail system 50 to have a horizontal extent that serves as a delivery port 150 (see FIG. 4A ) below at least one of the delivery columns 119, 120.

[0134] 4A and 4B show a delivery rail system 50 extending from a location inside the storage grid 104 to a location outside the storage grid 104. One or more second locations, e.g., structures for picking and placing product items in storage containers 106, may be located anywhere in the delivery rail system 50 that is positioned outside the storage grid 104. Alternatively or in addition, a conveyor may be located at or near the same perimeter of the delivery rail system 50.

[0135] FIG. 4C shows a side view of an automated storage system including an automated storage grid 104 and a delivery system 140. The delivery system 140 includes a delivery vehicle 30 adapted to travel on a delivery rail system 50 positioned below delivery ports 150 (not shown in FIG. 4C, see FIG. 4A or FIG. 4B) of delivery columns 119, 120 of the storage grid 104. Container handling vehicles 200, 300 operate on the rail system 108 to pick up and drop storage containers through the delivery columns 119, 120. The delivery vehicle 30 is operated so that it can accept or deliver storage containers 106 to the delivery ports 150. The container storage column 105 is shown in FIG. 4C without containing a storage container 106. In operation, the storage column 105 is filled with storage containers 106 stacked on top of each other, and ... There are.

[0136] The distribution system can benefit from many of the considerations provided for the container handling vehicle rail system 108 of the storage grid 104 and the container handling vehicles 200, 300. As shown in FIG. 4C, the uprights 102 of the storage grid 104 are shortened and suspended on a mezzanine level 151, which itself has upright posts that can be extended out from the distribution columns 119, 120. As a result, the adoption of the distribution system 140 represents a loss of storage space in the storage grid 104. However, the benefit is an improved distribution efficiency of the storage containers 106 in the automated warehouse system, since congestion of the storage containers 106 in the distribution columns 119, 120 is avoided or at least reduced. The number of distribution columns 119, 120 and the size (extent) of the mezzanines in the X and Y directions can be customized according to the size of the storage system and the desired efficiency of the system.

[0137] Figure 5 is a perspective view of an automated warehouse system including an automated warehouse grid and a distribution system. Most of the features of the system disclosed in Figure 5 are similar to those described above with respect to Figures 4A-4C, except that a robot operator 160' is disclosed.

[0138] As disclosed in FIG. 5, two robot operators 160′ are disposed on a floor base 169 adjacent to the delivery rail system 50. Each of the robot operators 160′ is disclosed as having one robotic arm and configured to pick and place a product item or goods into a storage container 106, and optionally into a shipping container (not shown in FIG. 5) that is disposed at a third location outside the delivery rail system 50 for further transportation. Although the robot operators 160′ are disclosed with one robotic arm, it is apparent that one robot operator 160′ can have more than two robotic arms, for example, two, three, four, five, ..., nine, ten arms, and more.

[0139] The robot operator 160' can be operated to move in X, Y and Z directions, thereby enabling access to storage containers 106 at different locations within the delivery rail system 50 and transferring at least one product item between the storage containers 106 within the delivery rail system 50 and a third location outside the delivery rail system 50. The length of the robot arm of the robot operator 160', as well as other characteristics of the robot arm, can be adjusted according to requirements within a particular project, such as, for example, the number of delivery vehicles 30, the size of the delivery rail system 50, the number of robot operators 160', etc.

[0140] Figures 6A and 6B are two different perspective views of an automated warehouse system including an automated warehouse grid 104 and a distribution system 140. Most of the features of the system disclosed in Figures 6A-6C are similar to those described above with respect to Figures 4A-4C, except that a gantry arrangement 165 with a suspended robotic operator 160'', a conveyor belt 153, and a human operator 164 operating at a manual handling or picking station 168 are disclosed.

[0141] A gantry structure 165 is disposed above parts of the delivery rail system 140, and a robot operator in the form of at least one robot arm is suspended from a horizontal bar 167 within the gantry structure 165. The robot arm 160" disclosed in FIGS. 6A and 6B is different from the robot arm 160' disclosed in FIG. It may be different or may be similar to the robot arm 160' disclosed in FIG.

[0142] The gantry structure 165 can be, for example, a floor-mounted system as disclosed in FIGS. 6A-6C that includes vertical beams 166 disposed on either side of the delivery rail system 50 connected at the top by a horizontal bar 167. Alternatively, the gantry structure 165 can be, for example, a ceiling-mounted bar (not shown) that extends in the X and Y directions similar to the delivery rail system 50 below. In either case, one or more robot operators 160″ can be suspended from the gantry structure 165.

[0143] The gantry structure 165 can span at least a portion of the delivery rail system 50. Moreover, at least one robotic arm 160″ can be configured to move in XYZ directions along bars and / or beams 166, 167 in the gantry structure 165 to enable access to storage containers 106 at different locations in the delivery rail system 50.

[0144] At least a portion of the gantry structure 165 may be laterally offset from the delivery rail system 50. The at least one robotic arm 160″ may be configured to travel laterally along a horizontal bar 167 of the gantry structure 165 to deliver or retrieve at least one product item to or from a third location outside the delivery rail system 50.

[0145] As further disclosed in FIGS. 6A-6C and 7, the conveyor belt 153 may be positioned at or near the periphery of the delivery rail system 50.

[0146] Additionally, a human operator 164 may cooperate with the robot operator 160". The human operator 164 may, for example, operate a manual handling or picking station 168. The delivery rail system 50 may extend into the handling or picking station 168 such that the delivery vehicle 30 may transport storage containers directly to the human operator 164. The human operator 164 is preferably protected from the delivery vehicle 30 by a physical barrier. The physical barrier may be in the form of a fence (not shown) or the like, or as illustrated in FIGS. 6A and 6B, any side walls and / or lids in the handling or picking station 168 may be formed from a reinforced material.

[0147] The conveyor belt 153 may extend from a location (not shown) where the shipping container 162 is placed onto the conveyor belt 153 (e.g., the shipping container is placed onto the conveyor belt 153 either automatically or manually), through a distribution system 140 for insertion of product items into or removal from the shipping container 162, to an area (not shown) where the shipping container 162 is collected for further transportation or shipping, e.g., a car, a larger container, a truck, etc.

[0148] FIG. 6C is an alternative to the system disclosed in FIGS. 6A and 6B and shows a larger system with four delivery rail systems 140 and four gantry structures 165, one gantry structure 165 positioned above each of the four delivery rail systems 140.

[0149] 7A-7B are different perspective views of an automated warehouse system including an automated warehouse grid 104 and a delivery system 140, which includes a common delivery rail system and four robotic operators. The robotic operators 160' are in the form of at least one robotic arm 160' supported on a floor base 169 adjacent the delivery rail system 50 for picking and placing items between the storage containers 106 and the shipping containers 162 on the conveyor belt 153.

[0150] A plurality of entry lines 161 for guiding the empty transport containers 162 to any one of the conveyor belts 153 may be provided at each of the locations where the robotic operators 160' are located (i.e., the second locations). The entry lines 161 with the empty transport containers 162 may be a system as disclosed in FIGS. 7A and 7B or other suitable systems. In the system disclosed in FIGS. 7A and 7B, the empty transport containers 162 are fed from a conveyor feed system 163 with a plurality of separate entry openings leading to each of the entry lines 161. The entry lines 161 may feed the transport containers 162 by gravity (i.e., by inclining the entry lines 161 relative to the second locations or by using a conveyor mechanism, etc.). When one robot operator indicates that it is finished placing a product item into a shipping container 162, the system may be operated such that a new empty shipping container 162 enters the entry line 161 and thus the conveyor belt 153 associated with said entry line 161. Although not shown in Figures 7A-7B, a human operator, floor-based and / or base-mounted robot operator 160' may assist / collaborate with any of the robot operators 160'.

[0151] Alternatively, the system can include a third location (not shown) in addition to or as an alternative to the conveyor belt 153. The third location can be a temporary location for storage of multiple product items. At least one robotic arm 160', 160" can be configured to deliver at least one product item to the temporary location.

[0152] The temporary location may be a shipping container 162 for storing one or more product items, for example, for use in situations where multiple product items are to be shipped to the same client in one common shipment (i.e., to avoid multiple smaller shipments to the same client).

[0153] 8A-8B show different perspective views of an automated warehouse system including an automated warehouse grid 104 and a distribution system 140 with a common distribution rail system 50 and one common gantry structure 165 with a horizontal beam 167 spanning the entire width of the distribution rail system 50.

[0154] A number of robot operators 160″ in the form of robot arms are suspended from a horizontal bar 167 in a gantry structure 165. The gantry structure 165 from which the robot operators 160″ are suspended, and the robot operators 160″ may be similar to the gantry structure 165 and robot operators 160″ described with respect to FIGS. 6A and 6B above. Similarly, the features of the entry line 161 and the shipping container 162 may be similar to the system described with respect to FIGS. 7A and 7B above. Although not shown in FIGS. 8A-8B, a human operator 164 may assist / collaborate with any of the robot operators 160′, 160″.

[0155] FIG. 9A shows an example of a distribution rail system 50 located adjacent to the rail system 108 on which the container handling vehicle 300 operates, with two gantry structures 165 with suspended robotic operators 160″ positioned in the transition zone between the two rail systems 50, 108, and the distribution rail system 50 including an item aggregation area 410 for receiving picked product items 405 for further transport.

[0156] FIG. 9B shows details of the item aggregation area 410 of FIG. 9A, which is disclosed as including five conveyors 408 and multiple horizontal openings 407 for receiving and further transporting the picked product items 405.

[0157] FIG. 9C is a side view of an aggregation vehicle 400 operable on the distribution rail system 50, the aggregation vehicle 400 being disclosed as having an openable side wall 403 for passing product items 405 from the item carriers 401 of the aggregation vehicle 400 and into a horizontal opening 407 in the distribution rail system 50 for further transportation.

[0158] Figures 10A and 10B disclose an aggregation vehicle 400 equipped with an actuator 406 for opening (Figure 10B) and closing (Figure 10A) an openable side wall portion 406 of the aggregation vehicle 400 so that product items 405 can be removed from the item carriers 401 of the aggregation vehicle 400.

[0159] 10C and 10D disclose an aggregation vehicle 400 with an openable bottom section 404, allowing product items 405 in item carriers 401 in the aggregation vehicle 400 to fall by gravity, preferably through an underlying horizontal opening 407 to a lower level of the aggregation vehicle 400 for further transport.

[0160] FIG. 10E discloses (starting from the left to the right in the figure) a delivery rail system 50 with a handling or picking station 168; an item picking area 409 with a robotic operator 160″ for moving product items 405 between storage containers 106 being carried by the delivery vehicle 30; and an item picking area 409 with a robotic operator 160″ for moving product items 405 from the storage containers 106 to item carriers 401 on the aggregation vehicle 400. The storage containers 106 may be transported to the item picking area 409 by the delivery vehicle 30 (see FIGS. 10E, 10F), i.e., the item picking area 409 serves as a second location, where the product items 405 in the storage containers 106 may be picked from the storage containers 106 by the robotic operator 160′, 160″ and the picked product items 405 may be placed into another storage container 106 or into an item carrier 401 on the aggregation vehicle 400.

[0161] FIG. 10F shows details of an item picking area 409 with a robotic operator 160'' for moving product items 405 from the storage containers 106 to the item carriers 401 of the aggregation vehicle 400 of FIG. 10E.

[0162] 9A-9C and 10A-10D, the aggregation vehicle 400 may be movable in both the X- and Y-directions on the distribution rail system 50 (including locations on the distribution rail system 50 where the robotic operators 160′, 160″ can place product items 405 into or pick up product items 405 from the item carriers 401 on the aggregation vehicle 400). Such locations on the distribution rail system 50 are referred to herein as item picking areas 409. The item carrier 401 has four side walls 402, 403, and 404. 3, a bottom section 404, and an open top, and one of the side walls 403 or the bottom section 404 may be openable so that the product items 405 may be removed from the item carrier 401 horizontally or vertically, respectively, in the item collection area 410. The item collection area 410 may include a conveyor 408, which is preferably flush with or somewhat lower than the bottom section 404 of the item carrier 401 and / or the horizontal opening 407 inside the delivery rail system 50. The item collection area 410 is an area where the collection vehicle 400 may be positioned to remove the product items 405 stored in the item carrier 401 before the product items are further transported, for example to a packaging / processing assembly. To allow this, one of the side walls 403 or the bottom section 404 may be a trap door / hatch.

[0163] In an embodiment, one of the sidewalls 403 or bottom section 404 may be connected to an actuator 406 (see FIGS. 9A, 9C, 10A, 10B) such that the sidewalls 403 or bottom section 404 may be opened or closed by activating the actuator 406. In other words, the openable sidewalls 403 or bottom section 404 provide an opening in the item carrier 401 when the openable sidewalls 403 or bottom section 404 are in an open position. Alternatively, one of the sidewalls 403 or bottom section 404 is comprised of or includes at least one actuating surface.

[0164] The aggregation vehicle 400 may include wheel structures 32a, 32b (see Figures 10A, 10B) for moving the aggregation vehicle 400 in two perpendicular directions on the delivery rail system 50.

[0165] The openable sidewall 403 or bottom section 404 may include a hinged surface or sidewall 403. The openable sidewall 403 may be positioned relative to a conveyor 404 (see FIG. 10B) forming the bottom section 404 in the aggregation vehicle 400 such that when the sidewall 403 is open, the product items 405 are not restricted by the sidewall 403 from being ejected sideways under the influence of movement by the conveyor 404 disposed in the bottom section 404 of the item carrier 401. The conveyor 404 may include a belt, rollers, etc. As an alternative to a conveyor, a push arrangement may be provided that pushes any items out of the item carrier.

[0166] The openable side wall 403 may be hinged at its upper end so that its lower end is raised when in the open position.

[0167] The item aggregation area 410 (see FIGS. 9A-9C) can include a horizontal opening 407 or conveyor 408 positioned to guide the product items 405 exiting the aggregation vehicle 400 to a packaging / processing assembly. The conveyor 408 (preferably a belt conveyor 408) can be positioned to guide and transport the product items 405 laterally.

[0168] The opening 407 may be located at a level below the delivery rail system 50.

[0169] The opening 407 may be positioned above a packaging / processing assembly (not shown), such as a belt conveyor featuring packaging boxes, so that product items 405 from the aggregation vehicle 400 may be guided into the packaging boxes. .

[0170] The distribution rail system 50 may be a dual track rail, allowing two aggregation vehicles 400 to pass each other over adjacent grid cells of the distribution rail system 50.

[0171] The aggregation vehicle 400 may have a horizontal perimeter that fits within the horizontal area defined by the grid cells 122' of the distribution rail system 50 (see FIG. 9B).

[0172] The wheel arrangement 32a, 32b of the aggregation vehicle 400 may include eight wheels, with a first set of four wheels 32a allowing lateral movement of the aggregation vehicle in a first direction and a second set of the remaining four wheels 32b allowing lateral movement in a second direction perpendicular to the first direction. One or both sets of wheels 32a, 32b in the wheel arrangement may be connected to a wheel lifting mechanism and may be raised and lowered such that the first set of wheels 32a and / or the second set of wheels 32b may be engaged with the respective underlying delivery rail system 50 at any one time.

[0173] The aggregation vehicle may include an actuator 406 connected to the openable sidewall or bottom section. The actuator 406 may be arranged to move the sidewall 403 and bottom section 404, respectively, between an open position and a closed position. In the open position, product items 405 located within the item carrier 401 may be ejected from the item carrier 401. Alternatively, one of the sidewall 403 or bottom section 404 may be comprised of or include at least one actuating cover.

[0174] 10E and 10F , according to further embodiments, or in addition to the foregoing, the robotic operators 160′, 160″ may be configured to rearrange or reposition the product items 405 within the storage containers 106 or item carriers 401, and / or to move product items between storage containers 106 (e.g., storage containers 106 being carried by a delivery vehicle 30 as described herein) and / or between item carriers 401 in an aggregation vehicle 401. The robotic operators 160′, 160″ may be configured to rearrange or reposition the product items 405 within the storage containers 106, between different storage containers 106, and / or between storage containers and item carriers in an aggregation vehicle. Such reordering, rearrangement, and / or movement of the product items 105 therein may be performed in a dedicated item picking area 409 in the delivery rail system 50. A robot operator 160″ (illustrated in FIGS. 10E and 10F as a robot operator 160″ suspended from a gantry arrangement 165) may be configured to transfer the product items 405 between storage containers 106 being carried by the delivery vehicle 30 prior to storage of at least one of the storage containers 106 and / or before at least one of the storage containers 106 is presented for picking of the product items 105 therein (which picking may be performed, for example, at a handling or picking station 168).

[0175] Thus, the robot operator 160" may be configured to organize the product items 405 in the warehouse system and / or may be used to refine the contents of a storage container 106, for example, before the storage container 106 is presented for selection of the product items 405 therein, for example, for delivery, etc. For example, when one storage container 106 is nearly empty and the remaining product items 405 are similar to the same product item, the robot operator 160" may be used to refine the contents of a storage container 106 before the storage container 106 is presented for selection of the product items 405 therein, for example, for delivery, etc. This can be advantageous when a robot operator 106" picks or finishes a portion of a product order in an item carrier 401 in the aggregation vehicle 400, where the product order is then moved to another storage container 106 equipped with an item carrier system 405, or for presentation at a handling or picking station 168, or for transfer through an openable side wall section 403 or bottom section 404 directly to, for example, a horizontal opening 407 or a conveyor 408 (see Figures 9A, 9B) in an item aggregation area 410.

[0176] Such a transfer may be performed by utilizing an item picking area 409, for example by using the setup of FIG. 10A, where the robotic arm 160″ can pick the product item 405 from the storage container 106 in the first remote operated delivery vehicle 30, and then a second remote operated delivery vehicle 30 with the storage container 106 can replace the first remote operated delivery vehicle 30 or position itself within the reach of the arm of the robotic operator 160″, and then the arm 16 10F, one or more delivery vehicles 30 can position themselves next to an aggregation vehicle 400, with all vehicles 30, 400 being within reach of the arm of the robot operator 160”. The example of FIG. 10F provides the possibility to position up to eight vehicles (both delivery vehicles 30 and aggregation vehicles 400) at a time in the item picking area 409 (i.e., within the reach of the arms of the robotic operator 160″). The robotic operator 160″ can then pick product items 405 from one or more of the storage containers 106 being carried by the delivery vehicles 30 and place the product items 405 into item carriers 401 in the aggregation vehicle 400 for handling or presentation at the picking station 168 or for direct transfer through the openable side wall section 403 or bottom section 404 to a horizontal opening 407 or conveyor 408 in the item aggregation area 410 (see FIGS. 9A, 9B ). In this latter solution, the second location and / or the third location can be the item carrier 401 in the aggregation vehicle 400.

[0177] Additionally or alternatively, the robot operator 160" can move all product items 405 from one container 106 into another container 106, for example combining partially empty storage containers 106 to create a full container 106 and a spare empty container 106. Conversely, the robot operator 160" can evenly distribute the product items 405 from the storage containers 106 to ensure that multiple storage containers 106 have the required product items 405 and improve access efficiency for that product item 405 type. In this latter solution, the second and / or third location can be a storage container 106 on another remote-operated delivery vehicle 30.

[0178] Moreover, as noted above, and with reference to FIG. 10E , the robotic operator 160″ in the item picking area 409 may also be used as part of a process of reordering the product items 405 in the storage containers 106 before the storage containers 106 with the product items 405 are presented to an operator 164 at a handling or picking station 168. The product items 405 in the storage containers 106 may have been picked by the robotic operator 160″, or the storage containers 106 may be moved by the robotic operator 160″ from a stack of storage containers 106 under the container handling vehicle rail system 108. 107. An operator 164 at the handling or picking station 168 may then only need to verify the storage container contents before the storage container 168 is prepared for further transportation or shipping. If the product items 405 are randomly arranged in the storage container 106, the robotic operator 160" may be utilized to organize or reorganize the product items 405 at an intermediate pre-picking stage, so that when the storage container 106 arrives at the handling or picking station 168, the product items 405 are automatically organized and all of the product items 405 are visible from above by the human operator 164 or a camera (the operator may then be in another location and simply verify the contents in the storage container by controlling a snapshot taken by the camera of the product items in the storage container).

[0179] Such a method may include picking at least one product item 405 from the storage container 106 by a robotic operator 160′, 160″ after the storage container 106 is transported by the delivery vehicle 30 to a second location (e.g., an item picking area 409) and automatically placing the picked product item 405 into the same storage container 106, e.g., to reorder the product items 405 in the storage container 106.

[0180] Moreover, the robot operators 160', 160" may also be used as part of a process of reorganizing different categories of product items 405 stored in one common storage container 106 into multiple other storage containers 106 (e.g., one storage container 106 for each different product category). For example, one storage container 106 may contain various medications from one medication provider and may be stored in the automated warehouse grid 1. The automated warehouse system may then, whenever it has the time and capacity, bring this storage container 106 with the different medications to the robot operator 405 at a second location (e.g., item picking area 409) so that the robot operator 160" can place one type of medication in each storage container 106.

[0181] Such a method may include, after the storage container 106 is transported to the second location by the delivery vehicle 30: - picking at least one product item 405 from a storage container 106 by a robot operator 160', 160" and placing the picked product item 405 in another respective storage container 106.

[0182] Common to all the different robot operators 160′, 160″ described above, they may be provided with suitable gripping devices and any necessary auxiliary equipment, e.g., cameras, lights, distance sensors, etc., depending on the demands in a particular project and the size and shape of the product items. Such equipment will be known to those skilled in the art and will not be further specified herein. Moreover, the means required for suspending the robot operator 160″ on the horizontal beam 167 of the gantry arrangement 165 can be any means that provides the desired functionality of movement in XYZ directions relative to the underlying delivery rail system 50, which means will be known to those skilled in the art and will not be further described herein. Similarly, any fastenings (i.e., any means that provide the necessary stability) required for a floor-based mounted robot operator 160′ or a base on the delivery rail 50 will be known to those skilled in the art and / or facilitate the possibility of rotational movement of the robot operator 160′ relative to the floor base 169 or delivery rail base (not shown).

[0183] The present invention provides a highly efficient automated warehouse system that is easy to install and whose delivery capacity can be easily increased after installation is complete.

[0184] In the preceding description, various aspects of an automated warehouse system and associated methods for picking product items using a robotic operator have been described with reference to illustrative embodiments. For purposes of explanation, specific numbers, systems, and configurations have been set forth to provide a thorough understanding of the system and its operation. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments, as well as other embodiments of the system that are apparent to those skilled in the art of the disclosed subject matter, are deemed to be within the scope of the present invention. [Explanation of symbols]

[0185] 1. Automated warehouse system 30 Delivery Vehicles 31 Vehicle body 32 Rolling Device 32a 1st set of wheels 32b Second set of wheels 35 Container Carrier 36 Conveyor 45 Lifting Arm 50 Delivery Rail System 51 First set of parallel rails 52 Second set of parallel rails P1 Horizontal plane of the distribution rail system 100 Framework Structure 102 Framework structure upright members 103 Horizontal members of framework structures 104 Storage Grid / 3D Grid 105 Storage Column 106 Storage Container 107 Stack 108 Rail System / Container Handling Vehicle Rail System 110 a first set of parallel rails in a first direction X 112 Grid Column 111 a second set of parallel rails in a second direction Y 115 Grid Opening 119 Shipping Column 120 Shipping Column 122 grid cells 122' Grid Cell Delivery Rail System 140 Delivery System 150 Shipping Ports 151 Mezzanine Level 153 Conveyor Belt 160' Floor-Based Wearable Robot Operator Robot operator suspended from 160” gantry structure 161 Entry Line 162 Shipping Container 163 Conveyor Feeding System 164 Human Operator 165 Gantry Component 166 Vertical Beam 167 Horizontal Bars 168 Handling or Picking Station 169 Floor Base 200 First container handling vehicle 201 Wheel structure 300 Second container handling vehicle 301 Wheel structure X First Direction Y Second Direction Horizontal Plane of the P-Rail System P1 Horizontal plane of the distribution rail system 400 aggregate vehicles 401 Item carrier in a collection vehicle 402 Side wall 403 Openable side wall 404 Bottom Section 405 product items 406 Actuator 407 Horizontal openings 408 Conveyor 409 Item Picking Area 410 Item Collection Area

Claims

1. A delivery system (140), comprising: a distribution rail system (50), said distribution rail system (50) comprising a first set of parallel rails and a second set of parallel rails, said first set of parallel rails being arranged in a horizontal plane (P1) and extending in a first direction (X), and said second set of parallel rails being arranged in said horizontal plane (P1) and extending in a second direction (Y) perpendicular to said first direction (X); one or more remote-operated delivery vehicles (30) configured to travel on said delivery rail system (50), each of said one or more remote-operated delivery vehicles (30) including a container carrier (35) adapted to support a storage container (106); a second location of said distribution rail system (50), said second location comprising a robot operator (160'; 160") for the handling of product items in said storage containers (106); Including, the one or more remotely operated delivery vehicles (30) are configured to transport the storage containers (106) between a first location and the second location, and the robotic operator (160'; 160") is capable of reaching multiple locations in the distribution system to access storage containers (106) transported on the one or more remotely operated delivery vehicles and located at different locations in the distribution system; A delivery system (140).

2. 2. The delivery system of claim 1, further comprising a gantry structure (165) above the one or more remotely operated delivery vehicles (30), the robotic operator (160") in the form of at least one robotic arm (160") being suspended from the gantry structure (165).

3. 3. The distribution system of claim 2, wherein the gantry structure (165) spans at least a portion of the distribution rail system (50), and the at least one robotic arm (160") is configured to move in X, Y and Z directions to access storage containers (106) at different locations within the distribution rail system (50).

4. 4. The distribution system of claim 2 or 3, wherein at least a portion of the gantry structure (165) is laterally offset from the delivery rail system (50), and the at least one robotic arm (160") is configured to travel laterally along the gantry structure (165) to deliver the at least one product item to or retrieve the at least one product item from a third location outside of the delivery rail system (50).

5. 4. The distribution system of claim 2 or 3, wherein at least a portion of the gantry arrangement (165) is laterally offset from the delivery rail system (50), and the at least one robotic arm (160") is configured for insertion of product items to or removal of product items from a third location outside of the delivery rail system (50) by varying a range of robotic arm lengths.

6. 2. The distribution system of claim 1, wherein the robot operator (160') is in the form of at least one robot arm (160') supported on a floor base (169), on a base above the distribution rail system (50), or on the distribution rail system (50).

7. The delivery system of claim 1 , wherein the one or more remotely operated delivery vehicles (30) include a plurality of remotely operated delivery vehicles.

8. 1. A method of transporting a storage container (106) to a second location in a distribution system (140) for handling product items in the storage container (106) by a robotic operator, comprising: The delivery system (140) comprises: a distribution rail system (50), said distribution rail system (50) comprising a first set of parallel rails and a second set of parallel rails, said first set of parallel rails being arranged in a horizontal plane (P1) and extending in a first direction (X), and said second set of parallel rails being arranged in said horizontal plane (P1) and extending in a second direction (Y) perpendicular to said first direction (X); one or more remote-operated delivery vehicles (30) configured to travel on said delivery rail system (50), each of said one or more remote-operated delivery vehicles (30) including a container carrier (35) adapted to support said storage container (106) and mounted above a vehicle body (31); Including, The method comprises: positioning one of said one or more remotely operated delivery vehicles (30) at a first location to receive said storage container (106) onto said container carrier (35) provided on said remotely operated delivery vehicle (30); - transporting said storage container (106) to said second location using said remotely operated delivery vehicle (30); using at least one robotic operator (160'; 160") to pick at least one product item from the storage container (106) at the second location, the robotic operator (160'; 160") being capable of reaching multiple locations in the distribution system to access storage containers (106) transported on the remote-operated delivery vehicle and located at different locations in the distribution system; A method comprising:

9. The method of claim 8, further comprising the step of operating said one of the one or more remotely operated delivery vehicles (30) to move by operating a rolling device (32) of said one of the one or more remotely operated delivery vehicles (30).

10. The method comprises: The method of claim 8 or 9, further comprising the step of utilizing said robot operator (160") in the form of at least one robotic arm (160") suspended from a gantry arrangement (165) above said remotely operated delivery vehicle (30).

11. The method comprises: The method according to claim 8, further comprising the step of utilizing said robot operator (160') in the form of at least one robotic arm (160'), said at least one robotic arm (160') supported on a floor base (169), on a base above the delivery rail system (50) on which the remotely operated delivery vehicle (30) operates, or on the delivery rail system (50) on which the remotely operated delivery vehicle (30) operates.

12. The method comprises: The method of claim 11, comprising the step of moving the at least one robotic arm (160') in XYZ directions to access storage containers (106) at different locations in the distribution rail system (50) and to transfer the at least one item between the storage containers (106) in the distribution rail system (50) and a third location outside the distribution rail system (50).

13. The method further includes, after the storage container (106) is transported to the second location by the one of the one or more remotely operated delivery vehicles: The method according to claim 8, comprising the step of picking at least one product item from the storage container (106) by the robot operator (160'; 160") and automatically placing the picked product item into the same storage container so as to reorder the product items in the storage container (106).

14. The method further includes, after the storage container (106) is transported to the second location by the one of the one or more remotely operated delivery vehicles: The method according to claim 8, comprising the step of picking at least one product item from the storage container (106) by the robot operator (160'; 160") and placing the picked product item in another storage container (106).

15. The method of any one of claims 8 to 14, wherein the one or more remotely operated delivery vehicles (30) comprise a plurality of remotely operated delivery vehicles.

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