Multi-function inventory handling station assembly

Abstract

To provide a stock handling station assembly for a storage and collection system.SOLUTION: A stock handling station assembly (60) comprises: a supply zone (64) comprising at least one upright column and a vertical chute (62); a buffer zone (70) comprising at least one box elevating device (68); an access station (66) intermediate between the supply zone (64) and the buffer zone (70) in order to enable an access to one or a plurality of containers going out of the supply zone (64); and a conveyor system (76) constituted so as to convey the one or the plurality of containers from the supply zone (64) to the buffer zone (70) via the access station.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to the field of storage and retrieval systems for handling storage containers or bins stacked within a grid framework structure, and more particularly to a further multi-function inventory handling station assembly for retrieving or supplying one or more items or goods to or from a storage and retrieval system comprising a grid framework structure. [Background technology]

[0002] Storage systems comprising a three-dimensional storage grid structure within which storage containers / bins are stacked on top of each other are well known. PCT Publication WO 2015 / 185628 A (Ocado) describes a known storage and procurement system in which stacks of bins or containers are arranged within a grid framework structure. The bins or containers are accessed by remotely operable baggage handling devices on tracks mounted above the grid framework structure. A system of this type is shown diagrammatically in Figures 1 to 3 of the accompanying drawings.

[0003] As shown in FIGS. 1 and 2, stackable containers known as boxes or bins 10 are stacked on top of each other to form stacks 12. The stacks 12 are arranged within a grid framework structure 14 in a warehousing or manufacturing environment. The grid framework is composed of a plurality of storage columns or grid columns 15. Each grid within the grid framework structure has at least one grid column for storage of a stack of containers. FIG. 1 is a schematic perspective view of the grid framework structure 14, and FIG. 2 is a top-down view illustrating the stack 12 of boxes 10 arranged within the framework structure 14. Each box 10 typically holds multiple product items (not shown), which may be the same or different product types, depending on the application.

[0004] The grid framework structure 14 includes a plurality of upright members or columns 16 that support horizontal members 18, 20. A first set of parallel horizontal grid members 18 are arranged perpendicular to a second set of parallel horizontal grid members 20 to form a plurality of horizontal grid structures supported by the upright members 16. The members 16, 18, 20 are typically fabricated from metal and are typically welded or bolted to one another, or a combination of both. The boxes 10 are stacked between the members 16, 18, 20 of the grid framework structure 14 such that the grid framework structure 14 protects the stack 12 of boxes 10 from horizontal movement and guides the vertical movement of the boxes 10.

[0005] The top level of the grid framework structure 14 includes rails 22 arranged in a grid pattern across the top of the stack 12. With further reference to FIG. 3 , the rails 22 support a plurality of load handling devices 30. A first set 22a of parallel rails 22 guides movement of the robotic load handling devices 30 in a first direction (e.g., the X direction) across the top of the grid framework structure 14, and a second set 22b of parallel rails 22, positioned perpendicular to the first set 22a, guides movement of the load handling devices 30 in a second direction (e.g., the Y direction) perpendicular to the first direction. In this manner, the rails 22 enable movement of the robotic load handling devices 30 laterally in two dimensions in the horizontal XY plane such that the load handling devices 30 can be moved to appropriate positions above either of the stacks 12.

[0006] A known luggage handling device 30, shown in FIGS. 4 and 5, includes a vehicle body 32 and is described in PCT Patent Publication WO 2015 / 019055 (Ocado), which is incorporated herein by reference, with each luggage handling device 30 covering only one grid space of a grid framework structure 14. Here, the luggage handling device 30 includes a wheel assembly including a first set of wheels 34, consisting of a pair of wheels at the front of the vehicle body 32 and a pair of wheels 34 at the rear of the vehicle 32, for engaging a first set of rails or tracks to guide movement of the device in a first direction, and a second set of wheels 36, consisting of a pair of wheels 36 on either side of the vehicle 32, for engaging a second set of rails or tracks to guide movement of the device in a second direction. Each of the set wheels is driven to enable movement of the vehicle in the X and Y directions along the rails, respectively. One or both sets of wheels are vertically movable to lift each set of wheels off their respective rails, thereby enabling movement of the vehicle in the desired direction.

[0007] The load handling device 30 is equipped with a lifting device or crane mechanism for lifting a storage container from above. The crane mechanism includes a winch, tether, or cable 38 wound on a spool or reel (not shown) and a gripping device 39. The lifting device or crane mechanism includes a set of lifting tethers 38, also referred to as gripping devices (one tether near each of the four corners of the gripping device), extending vertically and connected near or to the four corners of the lifting frame 39 for releasable connection to the storage container 10. The gripping device 39 is configured to releasably grip the top of the storage container 10, lifting it from a stack of containers in a storage system of the type illustrated in FIGS. 1 and 2.

[0008] The wheels 34, 36 are positioned around the periphery of a cavity or recess known as a container-receiving recess 40 in the lower portion of the load handling device. The recess is sized to accommodate the container 10 when it is lifted by a crane mechanism, as shown in FIGS. 5(a and b). When in the recess, the container is lifted off the lower rail to allow the vehicle or load handling device to move laterally to a different location. Upon reaching the target location, e.g., another stack, an access point in a storage system, or a conveyor belt, the box or container can be lowered from the container-receiving portion and released from the gripping device.

[0009] Thus, upon receiving a customer order, a luggage handling device operable to move on a track is instructed to retrieve a storage bin containing the ordered items from a stack within the grid framework structure and transport the storage bin to a pickup station, after which the items can be retrieved from the storage bin. Typically, the luggage handling device transports the storage bin or storage container to a box lifting device integrated into the grid framework structure. A mechanism of the box lifting device lowers the storage bin or storage container to the pickup station. At the pickup station, the items are retrieved from the storage bin. Retrieval can be performed manually by hand or by a robot as taught in GB2524383 (Ocado Innovation Limited). After retrieval from the storage bin, the storage bin is transported to a second box lifting device, which then lifts it to grid level for retrieval by the luggage handling device and transports it back to its location within the grid framework structure. A control system and communication system track the location of the storage bins and their contents within the grid framework structure. Because individual containers are stacked in vertical layers, their location within the grid framework structure or "hive" may be indicated using coordinates in three dimensions to represent the location of the baggage handling device or container and container depth (e.g., container at (X,Y,Z), depth W). Similarly, the location within the grid framework structure may be indicated in two dimensions to represent the location of the baggage handling device or container and container depth (e.g., container depth (e.g., container at (X,Y), depth Z)). For example, Z=1 identifies the top layer of the grid, i.e., the layer immediately below the rail system, Z=2 is the second layer below the rail system, and so on down to the bottom layer of the grid.

[0010] Similarly, when stocking or replenishing a storage system with items, items delivered from a supplier are transported to a decanting station or dispensing station, where the items are removed from their packaging depending on the type of item, registered into a unique stock keeping unit or SKU, and placed into a storage bin at the decanting station. At the decanting station, the storage bin is transported to a bin lifting device, which then lifts it to grid level for retrieval by a baggage handling device and transports it to a location within the grid framework structure.

[0011] WO2017 / 211640 (Autostore Technology AS) describes a storage system for storing product items, the storage system comprising a grid structure, wherein several storage bins are configured to be stored in vertical compartments within the grid structure, each storage bin configured to contain at least one product item, the storage system comprising a pick-up and / or supply station, and a conveyor system configured to transport the storage bins from a first position to a second position and further to a third position. The conveyor system comprises a first tiltable conveyor configured to transport the storage bins from the first position through the second position to the third position. The pick-up and / or supply station is located adjacent to the grid structure. The first and third positions are located below two different vertical compartments within the grid structure. The tiltable conveyor comprises a hydraulic piston and cylinder mechanism for lowering and raising the conveyor. The tiltable conveyor supports the storage bins in an inclined position in the second position, thereby allowing items to be manually removed from the storage bins. Once removed, the tiltable conveyor is tilted down and the storage bin is transported to a third position allowing it to be retrieved by a load handling device operable on the grid structure. While using a hydraulic piston and cylinder mechanism to lower and raise rollers suffers from alignment issues ensuring the storage bin can be transported from the first position through the second position to the third position, the use of such a tilting device adds a level of complexity to the retrieval station.

[0012] WO2018 / 069282 (Autostore Technology AS) describes a pick-up / supply station assembly for a storage system having a grid structure. The pick-up / supply station assembly includes a first box lifting device, a second box lifting device, and a pick-up / supply station, where the first box lifting device is positionable to receive storage boxes from at least one vehicle at an upper level of the grid structure and deliver the storage boxes to the pick-up / supply station. The pick-up / supply station includes a box transport assembly positioned to transfer storage boxes from the first box lifting device to the second box lifting device, and the second box lifting device is positionable to receive storage boxes from the box transport assembly and transport the storage boxes to the upper level of the grid structure. The box lifting device is positioned within the storage system to receive storage boxes from a vehicle or baggage handling device at the upper level of the grid structure and transport the boxes vertically down to a supply / picking station positioned on the first floor of a building in which the storage system is installed. In use, a first storage bin is initially placed on the lifting arms at the upper level of the grid and lowered toward the first conveyor unit. The lifting arms are spaced apart sufficiently to allow the first conveyor unit to pass between them. During the passage, the first storage bin remains on the first conveyor unit, while the lifting arms enter their lowest positions. The first storage bin is then transported from the first lifting device by the first conveyor unit. After the storage bin has exited the first box-lifting device, the lifting arms may return to the upper level to retrieve the second storage bin. The first box-lifting device and the second box-lifting device are integrated into the grid framework structure, and thus the removal station forms an integral part of the grid framework structure.

[0013] A similar box-lifting mechanism integrated into a grid framework structure for feeding a removal station is described in WO 2020 / 074717 (Autostore Technology AS). WO 2020 / 074717 (Autostore Technology AS) describes an access station for removing storage containers, the access station comprising a removal zone, and at least one conveyor arranged to transport the storage containers from an entry position through the removal zone to an exit position, the access station comprising at least one tilting device arranged to tilt the storage containers at least within the removal zone. Similarly, WO 2017 / 211640 (Autostore Technology AS) teaches that the tilting device tilts the storage containers within the removal zone when the access station is to be operated by a remover, thereby providing the ergonomic benefits of tilting. The storage containers are received at an entry position located on an entry conveyor at the rear of the access station. The entry locations are configured for connection to another conveyor, such as a storage system conveyor, that transports the storage containers to and from the entry location. Upon entering the access station, the entry conveyor transports the storage containers in a transport direction via a tiltable access conveyor to an exit conveyor within an unloading zone at the front of the access station. Entry and exit of the storage containers into the grid framework structure is through the rear of the access station. The entry and exit locations may each be connected to a storage system conveyor.

[0014] In a storage grid, the majority of grid columns are storage columns, i.e., grid columns where storage containers are stored in stacks. However, a grid typically has at least one grid column that is not used to store storage containers but that provides a location where container-handling vehicles can drop off and / or retrieve storage containers so that they can be transported to a second location (not shown in prior art figures) where the storage containers are accessible from outside the grid or can be transported to or from the grid. In the art, such locations are typically referred to as "ports," and the grid column where the port is located is sometimes referred to as a "delivery column." A storage grid includes two delivery columns. The first delivery column may, for example, include a dedicated drop-off port where container-handling or baggage-handling vehicles can drop off storage containers to be further transported through the delivery column to an access station or transfer station, and the second delivery column may include a dedicated pick-up port where container-handling vehicles can retrieve storage containers that have been transported through the second delivery column from the access station or transfer station. Storage containers enter the access station via a first delivery column and exit the access station via a second delivery column. However, this arrangement not only removes one or more grid columns for container storage, but also limits the access stations that are tied to specific grid columns within the grid framework structure for supplying and retrieving storage containers to and from the access stations.

[0015] While the access stations described above are suitable for fulfilling generally planned orders well in advance, e.g., several days before receipt of the customer order, no system is available for immediate fulfillment of customer orders, i.e., within a few hours of receipt of the customer order. This is particularly true when the order includes a small number of generally key items, e.g., bread or milk, and can also include impulse buying behavior of customers who tend to purchase items without prior planning. When customers make such purchasing decisions impulsively, it is often triggered by emotions or feelings, i.e., they make unplanned purchases. Convenience stores, which generally stock a wide range of everyday items such as coffee, groceries, snack foods, confectionery, soft drinks, tobacco products, over-the-counter drugs, cosmetics, newspapers, and magazines, tend to be best positioned to meet such impulse market demands. As the market for convenience stores and impulse purchases grows, access stations are therefore required to fulfill orders for immediate dispatch.

[0016] therefore, i) flexible and capable of serving as a pick-up station and / or a supply station; ii) It is portable so that it can be retrofitted to any grid framework structure; iii) Able to work with retrieval or supply stations within the storage system to source orders for immediate dispatch. An access station is required.

[0017] This application claims priority from GB Application No. GB2008129.5, filed May 29, 2020, the contents of which are incorporated herein by reference. Summary of the Invention

[0018] The present invention alleviates the above problems by providing an inventory handling station assembly for a storage and retrieval system, the storage and retrieval system comprising: a plurality of upright columns in one or more vertical planes arranged to form a plurality of grid columns in which one or more containers are stacked between the upright columns and vertically guided by the upright columns; a grid framework structure comprising: the plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members moving transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; the first set of grid members and the second set of grid members respectively support a first set of tracks and a second set of tracks for a load handling device to move one or more containers on the grid framework structure at an upper level of the grid framework structure; wherein the inventory handling station assembly comprises: i) a feeding zone comprising at least one vertical chute configurable to cooperate with at least one upright column, the at least one vertical chute having a first opening for receiving a container lowered by at least one baggage handling device through a grid cell and a second opening for allowing the container to exit the feeding zone; ii) a buffer zone for vertically stacking one or more containers comprising at least one box lifting device, each of the at least one box lifting device being positionable to lift a container upwardly towards the grid so that, in use, the container can be retrieved by at least one load handling device; iii) an access station intermediate the feeding zone and the buffer zone to allow access to one or more vessels exiting the feeding zone; iv) a conveyor system configured to transport one or more containers from the supply zone to the buffer zone via the access station; Equipped with.

[0019] For purposes of describing this invention, the terms "grid framework structure" and "framework structure" are used interchangeably to mean a three-dimensional structure for storage of containers. For purposes of describing this invention, the terms "grid" and "grid structure" are used interchangeably to mean a two-dimensional structure formed by a first set and a second set of horizontal members. The two-dimensional grid forms the top layer of the three-dimensional grid framework structure.

[0020] In comparison with access stations integrated into the grid framework structure of storage systems described in the art, the inventory handling station assembly of the present invention is a separate, stand-alone station capable of receiving storage containers or storage boxes from a load handling device operable on the grid framework structure. The grid framework structure can cooperate with the inventory handling station assembly so that one or more storage boxes or storage containers can be lowered into one or more chutes in the supply zone. Similarly, one or more box lifting devices in the buffer zone can vertically stack the storage boxes or storage containers before being removed by the load handling device operable on the grid. A drop port in the grid can cooperate with a delivery channel in the grid framework structure through which one or more storage containers are conveyed through a chute to supply one or more storage containers to the supply zone. Similarly, a removal port in the grid can cooperate with a return channel in the grid framework structure through which one or more storage containers can be removed from the box lifting device in the buffer zone. Storage boxes or storage containers are fed into the supply zone via at least one chute and transported to the buffer zone where they are vertically stacked for removal by a load handling device operable on the grid framework structure, i.e., on a track. For purposes of the present invention, "vertical chute" and "chute" are used interchangeably throughout this specification to refer to the same feature.

[0021] The supply zone, access station, buffer zone, and conveyor system are all modular in construction and easily retrofittable to existing grid framework structures. One or more chutes allow a baggage handling device operable on the grid framework structure to lower a storage bin under gravity and then transport the storage bin to the access station, where an operator or robotic device can gain access to the contents of the storage container. The access station according to one aspect of the present invention provides a flexible solution because it can be operated as both a removal station, where one or more items are removed from a storage container, and a replenishment station (also known as a decanting station), where one or more items are deposited into a storage container. For purposes of this invention, the terms "baggage handling device" and "bot" are used interchangeably throughout this specification to refer to the same feature.

[0022] Storage boxes or storage containers delivered to the supply zone are transported by the conveyor system through the access station to the buffer zone. The storage boxes or storage containers are paused at the pick-up station, where an operator selects a required item from the storage box or storage container and places the item in a customer delivery box or container. In the buffer zone, a box lifting device lifts the storage box or storage container toward the grid so that a baggage handling device operable at an upper level can retrieve the container. This allows one or more storage boxes or storage containers to be stacked vertically in the buffer zone. Preferably, the box lifting device lifts the storage box or storage container to the top level in the buffer zone above the conveyor system. More preferably, a baggage handling device operable at an upper level can grasp the storage box or storage container in the buffer zone and then lift the storage box or storage container into the container receiving space of the baggage handling device.

[0023] Preferably, the conveyor system includes an entrance conveyor unit, an exit conveyor unit, and at least one access conveyor unit, where the entrance conveyor unit is disposed within the supply zone and configured to convey storage bins or containers from the second opening of the at least one vertical chute to the at least one access conveyor unit in a first direction or first transport direction. The exit conveyor unit is disposed within the buffer zone and configured to convey storage bins or containers from the at least one access conveyor unit to the buffer zone in a second direction or second transport direction, where the at least one access conveyor unit is configured to convey containers from the supply zone to the buffer zone in a third direction or third transport direction. The three conveyor units provide flexibility in reducing the footprint of the inventory handling station assembly to convey one or more storage bins or containers from the supply zone to the buffer zone via the access station in multiple transport directions. For purposes of this specification, the terms "conveyor" and "conveyor unit" are used interchangeably. The terms "direction" and "transport direction" are used interchangeably and refer to the direction of transport of the conveyor or conveyor unit. The terms "first conveying direction" and "second conveying direction" are used to clarify from the terms "first direction" and "second direction" used above with respect to the first and second sets of grid members.

[0024] In one embodiment of the present invention, the entrance conveyor unit and the exit conveyor are arranged such that the first conveying direction of the entrance conveyor is opposite and parallel to the second conveying direction of the exit conveyor, and the third conveying direction of the at least one access conveyor unit is substantially perpendicular to both the first conveying direction of the entrance conveyor unit and the second conveying direction of the exit conveyor, respectively. Here, the exit from the at least one chute in the supply zone and the entrance to the at least one box lifting device face the same direction because they both discharge or accept storage boxes or storage containers in equal but opposite directions, respectively. The at least one access conveyor unit is perpendicular to both the entrance conveyor unit and the exit conveyor unit. Thus, the storage boxes or storage containers travel in a U-shaped direction through the conveyor system from the entrance to the supply zone, through the access station, and out into the buffer zone. As a result of this configuration, the storage boxes or storage containers change direction twice.

[0025] In another aspect of the invention, the conveyor system is arranged so that the first conveying direction of the entrance conveyor is perpendicular to both the second conveying direction of the exit conveyor and the third conveying direction of the at least one access conveyor. In this aspect of the invention, storage bins travel horizontally in an L-shaped direction from an entrance to the supply zone through the access station, then exit the access station into the buffer zone. This configuration results in a storage bin or container changing direction once as it enters at least one access conveyor unit. Both conveyor system configurations maximize the throughput of storage bins or containers through the inventory handling station assembly over a relatively small footprint compared to a grid framework structure. To further increase the throughput of storage bins or containers through the inventory handling station assembly, the at least one box lifting device is arranged so that some storage bins or containers travel in a U-shaped path and others travel in an L-shaped path, i.e., using both paths to increase the throughput of storage bins or containers through the inventory handling station assembly.

[0026] Preferably, the access station of the inventory handling station assembly of the present invention doubles as a supply station or a decant station where inventory stored within the grid framework structure is replenished with fresh stock. In this configuration, the access station functions as a decant station where fresh stock is pumped into storage bins or containers. The fresh stock arrives from the supply zone in the buffer zone and is then allocated to a designated vertical storage column or grid column within the grid framework structure by a load handling device operable on the grid framework structure. To keep track of the stock or inventory stored within the storage and retrieval system (i.e., the grid framework structure), at least one access conveyor unit preferably includes a load cell for weighing the containers. Preferably, the load cell is located below at least one access conveyor unit. More preferably, the load cell is located below at least one access conveyor unit such that the load cell is located at the access station. When operated as a removal station, the load cell measures the weight of the storage container within the access station each time an item is removed from the storage container. Optionally, one or more of the storage bins include a label readable by a user interface to establish the identity of each of the one or more storage bins when it is paused at the pick-up station. This allows the stock control system to identify the storage bin or container and correlate the contents of the storage bin or container with storage bins or containers stored within the grid framework structure. Optionally, the label on one or more of the storage bins may be a barcode, 1D barcode, 2D barcode, or QR code or RFID tag. A handheld scanner can be used to identify the identity of one or more of the storage bins, allowing the stock control system to correlate the contents of the one or more storage bins or containers with the identity of the storage bin or container itself.The weight reading is recorded along with the identification of the storage bin or container in an inventory or stock database, and the data is used to monitor and control the amount of stock in the storage system. For example, when the weight of a particular storage bin is less than its assigned predetermined weight, this provides information to the stock control system that the storage bin or container can hold more items. Preferably, the predetermined weight is between 15 kg and 50 kg, more preferably between 20 kg and 40 kg. An inventory or stock database is created that records the weight of each storage bin or container and their contents within the grid framework structure. The stock control system is used to track the location of each storage bin or container within the grid framework structure and the contents of each storage bin. For purposes of this specification, the terms "inventory database" and "stock database" are used interchangeably.

[0027] When the access station is operated as a supply station, the load cells measure the weight of the storage bin or storage container each time stock is added to the storage container. The lifting mechanism of the load handling device including the gripping device is rated to lift a predetermined weight above which the lifting mechanism including one or more motors is placed under undue tension. To ensure that the weight of the storage bin or storage container does not exceed the predetermined required weight of the lifting mechanism, the load cells measure the weight of the storage container each time an item is added to the storage container at the access station.

[0028] Preferably, the at least one access conveyor unit comprises a plurality of adjacent conveyor units arranged to transport storage bins or containers horizontally from the supply zone to the buffer zone via the access station. More preferably, each of the plurality of conveyor units is arranged to accommodate a single container, with at least one of the plurality of conveyor units comprising a load cell. Optionally, a work surface is arranged above the at least one access conveyor unit, the work surface having an opening allowing access to the contents of the storage container on the at least one access conveyor unit. Typically, the storage bins or containers are suspended on a particular conveyor unit of the at least one access conveyor unit.

[0029] At least one box-lifting device in the buffer zone allows processed storage bins or storage containers to be queued, preferably stacked vertically in the buffer zone, before being retrieved by a baggage handling device and deposited in their respective homes in the grid framework structure. For purposes of the present invention, a processed storage bin or storage container refers to a storage bin or storage container from which one or more items have been removed when the access station functions as a removal station, or loaded when the access station operates as a decanting / delivery station. The at least one box-lifting device prevents bottlenecking of storage bins within the access station, particularly at the work station, thereby reducing the throughput of storage bins through the inventory handling station assembly. Preferably, the at least one box-lifting device comprises two parallel arms engageable with a bottom wall of the storage container and a lifting mechanism arranged to move the two parallel arms vertically from the lowest level below the conveyor system to the highest level above the conveyor system, i.e., upward toward the grid. This allows a luggage handling device operable on the grid, e.g., a track, to subsequently retrieve a storage bin or container waiting at the highest level by grasping the storage bin or container and lifting it into a container receiving space of the luggage handling device. This allows the box lifting device, and thus the inventory handling station assembly, to be separated, e.g., disconnected, from the grid framework structure. The box lifting device allows one or more storage containers to be stacked vertically within a buffer zone as they pass through the access station. This increases the throughput of storage bins passing through the access station, thus improving the efficiency of the inventory handling station assembly of the present invention for processing or procuring orders when used as a retrieval station and / or replenishing stock when used as a supply station.

[0030] To allow one or more storage bins or containers to be stacked vertically within the buffer zone, the two parallel arms are preferably spaced apart a distance greater than the width of the exit conveyor unit. This allows the two parallel arms to vertically descend past the exit conveyor unit within the buffer zone. Thus, when a storage bin is lifted above the conveyor system and removed by a baggage handling device operable on the grid, the two parallel arms are commanded to descend past the exit conveyor unit in preparation for lifting another storage bin or container waiting on the exit conveyor unit. The two parallel arms can descend past a storage bin or container waiting on the exit conveyor unit within the buffer zone, allowing the lifting arms to position themselves downward and engage the bottom wall of the storage bin.

[0031] Preferably, at least one vertical chute includes at least two vertical guides for guiding a storage container vertically along the at least one vertical chute, each of the at least two vertical guides being receivable within a grid column of the grid framework structure. More preferably, each of the at least two vertical guides of the vertical chute includes two right-angle plates extending along the length of the vertical chute. The at least two vertical guides of each of the at least one vertical chute help guide a storage bin or storage container lowered by a load handling device onto an entrance conveyor unit in the supply zone. Preferably, the at least two vertical guides are spaced apart to cooperate with the grid columns, and more specifically, the upright columns of the grid framework structure are positioned to cooperate with the at least two vertical guides. This allows a load handling device operable on the grid to lower the storage bin or storage container through the grid cells down the vertical chute, where it descends onto an entrance conveyor unit in the supply zone. Preferably, the at least one vertical chute includes four vertical guides that cooperate with four corners of the storage container. More preferably, the inventory handling station assembly includes a sidewall surrounding each of the at least one vertical chute.

[0032] In another aspect of the present invention, A) a storage and retrieval system, the storage and retrieval system comprising a grid framework structure, the grid framework structure comprising: a) a plurality of upright columns arranged to form a plurality of grid columns in which one or more containers are stacked between the upright columns and vertically guided by the upright columns; wherein the plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members moving transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; the first set of grid members and the second set of grid members respectively support a first set of tracks and a second set of tracks at an upper level of the grid framework structure for a load handling device to move one or more containers on the grid framework structure; b) one or more containers stored within one or more grid columns, each of the one or more containers comprising one or more items having characteristic attributes; c) one or more luggage handling devices remotely operated to move one or more containers stored within the grid framework structure, each of the one or more luggage handling devices i) a wheel assembly for guiding the luggage handling device on the grid; ii) a container receiving space located above the grid; iii) a lifting device arranged to lift a single container from the stack into the container receiving space; Equipped with Equipped with B) The inventory handling station assembly and one or more load handling devices of the present invention are remotely operated to move one or more containers stored within the grid framework structure to and / or from the inventory handling station assembly. A procurement / replenishment system is provided, comprising:

[0033] For purposes of describing the present invention, the storage and retrieval system and the inventory handling station assembly are treated as separate components. However, the present invention is not limited to the inventory handling station assembly forming a separate part from the storage and retrieval system; the inventory handling station assembly can form part of the storage and retrieval system. In both cases, the procurement / replenishment system comprises the storage and retrieval system and the inventory handling station assembly. The items may be any goods or groceries. The goods or items may be packaged or bagged for shipment to customers.

[0034] Preferably, the plurality of grid columns comprises a first set of grid columns and a second set of grid columns, wherein the first set of grid columns are arranged to store one or more containers in a stack, and wherein the inventory handling station assembly is arranged below the second set of grid columns such that, in use, at least one vertical chute and at least one box lifting device are arranged below the at least one grid column such that a baggage handling device operable on an upper level of the grid framework structure can lower a container through the at least one grid column and down the at least one vertical chute, and the at least one box lifting device is operable to lift a container through the at least one grid column to be removed into the container receiving space of the baggage handling cell.

[0035] Not all grid columns are used to store one or more containers between the upright columns. Rather, they include locations, also referred to as ports, where a cargo handling device can drop off and / or retrieve storage bins or containers. A grid column in which a port is installed may be referred to as a delivery column, where one or more storage bins or containers are delivered to the supply zone. Similarly, a grid column in which a port is installed for retrieval of storage bins or containers may be referred to as a recovery column, i.e., where one or more storage bins are retrieved from the buffer zone. A first set of grid columns is arranged to form one or more vertical storage locations for one or more containers to be stacked between the upright columns, and a second set of grid columns is arranged to cooperate with at least one chute, and at least one box-lifting device is arranged to receive and discharge one or more storage bins or containers from the inventory handling station assembly. More specifically, the second set of grid columns includes at least one delivery column and at least one recovery column. The at least one delivery column is configured to cooperate with at least one chute in the supply zone, and the at least one box-lifting device is arranged to cooperate with the at least one recovery column.

[0036] Preferably, the inventory handling station assembly is disposed below the second set of grid columns such that, in use, a baggage handling device operable on the upper level of the grid framework structure can lower a container through the first grid column down the at least one vertical chute and at least one box lifting device is operable to lift a container to be removed through the second grid column into the container receiving space of the baggage handling cell, with each of the at least one vertical chute and at least one box lifting device being disposed below at least one grid column. Preferably, the one or more vertical chutes are disposed to be received within one or more grid columns of the second set of grid columns. More preferably, the second set of grid columns is supported by a mezzanine level. For example, grids from an adjacent grid framework structure are disposed to extend across the top of the mezzanine level to create a service area for the removal station and / or decanting station therebelow. The mezzanine level is supported by one or more vertical support beams, i.e., I-beams.

[0037] Preferably, the procurement / replenishment system further includes a bagging station, the bagging station including a table having a surface for supporting one or more bags and a user interface in communication with the bagging station control system. In one aspect of the invention, one or more items of a given order retrieved from one or more storage bins or containers in the access station are transferred to one or more bags for delivery to the customer. At least one user interface in communication with the bagging station control system provides an input device for acknowledging the retrieval of an item of the order from one or more storage bins or containers in the access station, i.e., acknowledging that the item of the order has been retrieved and loaded into a bag. This is repeated until all of the items of the order have been retrieved. Thus, each time one or more items are retrieved and loaded into a bag, an operator acknowledges the retrieval of one or more items of the order through an input device, preferably a user interface in communication with the bagging station control system. The bagging station control system can be separate from the central control system for information regarding where to retrieve and deliver containers or totes within the grid framework structure and / or the control system that controls the amount of stock or inventory stored within the storage and retrieval system, or some or all of these functions can be combined within the same control system.

[0038] Preferably, the table is divided into one or more spaces or compartments by one or more partitions, each of the one or more spaces or compartments comprising a user interface. Multiple orders of one or more items can be separated on the table by one or more partitions. The partitions are used to separate one or more bags on the table surface. Separation can be based on different customer orders or on attributes associated with the same order, such as frozen, refrigerated, or environmental items. Optionally, each of the one or more bags is a stand-alone bag. Acknowledgment that an item has been removed can be used to update a stock control system comprising an inventory database of remaining stock or inventory in the storage system.

[0039] One or more bags containing the order of procured items can optionally be delivered to a storefront for collection by a customer or a courier. Optionally, the one or more bags can be transferred to a plurality of electronically controllable lockers, each of which includes a compartment sized to accommodate one or more bags. As commonly known in the art, electronically controllable lockers can work in conjunction with a range of e-commerce platforms, such as click-and-collect models, in which items purchased online are transported from a procurement or distribution center to a collection point accessible by the customer. Procured orders are stored in electronically controllable lockers accessible by the purchasing customer or a courier, as taught in GB patent application GB2004400.4 (Ocado Innovation Limited), the contents of which are incorporated herein by reference. Other examples of the use of electronically controllable lockers are taught in GB240712B (Bearbox Limited), EP1366442B1, and EP2375386A2 (ByBox Holdings Limited).

[0040] The package handling device preferably comprises a control unit that receives control signals from a wireless communication unit of a control system or a central control system regarding information regarding where within the grid framework structure the containers or totes should be picked up and delivered, which control system may be separate from or the same control system that controls the amount of stock or inventory stored within the storage and retrieval system discussed above.

[0041] When used as a pick station, the control system is instructed to place and retrieve one or more storage containers containing one or more items of an order and deliver them to a supply zone of the inventory handling station assembly of the present invention, where they are then transported along a conveyor system to a pick station where the items are removed from the storage container or the box is removed to a delivery container. The storage box or storage container with remaining items is then returned to its assigned home within the grid framework structure. When the access station is used as a decanting station or supply station to replenish stock in the storage box or storage container, the load handling device is instructed to retrieve one or more storage containers from the assigned grid column or storage column. These may be empty storage containers or storage containers containing one or more items with a particular SKU (Stock Keeping Unit). Items, such as grocery items, have attributes that are characteristic of the item, such as manufacturer, brand, model, color, and / or size. Different items are distinguishable from one another by the characteristic attributes. One example of an attribute used by retailers to identify different stock or inventory is the stock control unit or SKU.

[0042] The retrieved storage container(s) are moved to a decanting or dispensing station within the inventory handling station assembly where items of a particular SKU are loaded into one or more storage containers or bins. The loaded storage bins or bins are then moved by a conveyor system to a buffer zone where they are stacked vertically until a load handling device or bot is free to return the storage bins or bins to their appropriate home within the grid framework structure, i.e., for storage within a grid column or storage column.

[0043] Traditionally, when fulfilling an order for one or more items, a control system including one or more processors and a memory that stores instructions when executed by the one or more processors is configured to instruct one or more package handling devices to retrieve one or more storage bins or containers for each item in the order. Thus, when fulfilling an order for multiple different items, the control system is configured to retrieve multiple storage bins or containers for each of the multiple different items identified in the order. While this is appropriate when there are multiple package handling devices operating on a grid framework structure that are capable of retrieving multiple storage bins or containers to fulfill a single order of multiple items, it is different in situations where multiple orders containing multiple items are required to be fulfilled within a tight time slot and / or there are a limited number of package handling devices available to retrieve the storage bins or containers necessary to fulfill the multiple orders. For example, there is a trend toward tighter time slots, e.g., immediate dispatch of orders within a few hours of receiving an order, than in traditional online retail, where orders are typically fulfilled over a period of several days. Convenience retailers, where orders are for staple grocery items such as milk, cheese, and beverages, are particularly popular.

[0044] In another aspect of the procurement / replenishment system of the present invention, the storage and retrieval system comprises: and one or more processors, and when executed by the one or more processors in response to receiving a plurality of orders, each of the plurality of orders comprising one or more items, the one or more processors; i) grouping or matching multiple orders based on at least one attribute of one or more items being common among the multiple orders; ii) generating a signal instructing a package handling device to retrieve a first container storing one or more items common to the plurality of orders; iii) generating a signal instructing a package handling device to lower the first container down at least one vertical chute through at least one grid column; iv) instructing a conveyor system to convey the first container to an access station such that one or more items common to the multiple orders can be transferred to multiple delivery containers associated with the multiple orders; v) a control system for instructing the conveyor system to transport the first container to the buffer zone; and a memory for storing instructions. Further provided are:

[0045] For purposes of the present invention, an item attribute corresponds to a particular characteristic of an item, such as manufacturer, brand, type, color, and size, and is often identified by a characteristic stock keeping unit (SKU). For example, a particular brand of cheese is identified by a characteristic SKU. To reduce the number of trips one or more package handling devices must undergo to retrieve multiple bins or storage containers to fulfill multiple orders, the control system includes one or more processors and memory storing instructions that, when executed by the one or more processors in response to receiving the multiple orders, cause the one or more processors to group or match the multiple orders based on at least one attribute of one or more items being common among the multiple orders. If one or more items are grocery items, the one or more grocery items are common or shared among the multiple orders. Here, the multiple orders can be matched or grouped based on each of the multiple orders including a particular grocery item, e.g., an order for cheese of a particular attribute, being shared among the multiple orders. The control system instructs the package handling device to retrieve a single storage bin or container if the contents of the storage bin or container comprise a grocery item, e.g., cheese of a particular attribute, such that the contents of the storage bin or container can be shared among multiple orders.

[0046] By grouping or matching multiple orders based on at least one attribute of one or more items being common among the multiple orders, items in a single storage bin or storage container can be shared among the multiple orders. This eliminates the need to repeatedly retrieve the same storage bin or storage container from the grid framework structure for multiple different orders. By matching or grouping multiple orders based on at least one attribute of one or more items being common among the multiple orders, the control system can generate a signal instructing a package handling device to retrieve a first container storing one or more items common to the multiple orders, instruct the package handling device to lower the first container down at least one vertical chute through at least one grid column, and generate a signal instructing a conveyor system to transport the first container to an access station such that the one or more items common to the multiple orders are shareable among multiple delivery containers associated with the multiple orders. For example, the delivery container can be a bag. By grouping or matching multiple orders based on at least one attribute of one or more items being common among the multiple orders, items from a single storage bin or storage container can be shared among multiple delivery bins, e.g., retrieved simultaneously, thus reducing the processing time for sourcing multiple orders. For purposes of the present description, a grid column in which at least one vertical chute is installed will be referred to as a delivery column, and a grid column in which at least one box lifting device is installed will be referred to as a retrieval column.

[0047] Preferably, the control system includes one or more processors: v) generating a signal instructing the package handling device to retrieve a second container storing one or more items common to the plurality of orders; vi) generating a signal instructing the baggage handling device to lower the second container through the at least one grid column and down the at least one vertical chute; vii) instructing the conveyor system to convey a second container to the access station such that one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders; viii) commanding the conveyor system to convey a second container to the buffer zone; The device is further configured to cause the instructions to be executed.

[0048] Preferably, the control system is further configured to cause the one or more processors to execute instructions to generate signals instructing one or more baggage handling devices to retrieve the first container and the second container from the buffer zone via at least one recovery column.

[0049] To further increase the efficiency of fulfilling multiple orders, the first container preferably includes one or more items with a first attribute and one or more items with a second attribute, where one or more items with the first attribute and / or one or more items with the second attribute are common among the multiple orders. In this case, the control system can match or group multiple orders of multiple different items based on the commonality or sharing of at least one item among the multiple orders. By storing multiple different items in a single storage bin or container, if each of the different items has a distinctive attribute, the control system can place and retrieve a single storage bin or container whose contents are shareable among multiple orders. This increases the likelihood that the contents of the storage bin or container are shareable among multiple orders. Therefore, fewer baggage handling devices are required to retrieve a storage bin or container to fulfill orders of one or more items.

[0050] Preferably, the storage and retrieval system of the procurement / replenishment system further comprises an order database comprising data associated with a plurality of orders for one or more items; wherein the control system is configured to access the order database to group or match multiple orders based on at least one attribute of one or more items being common among the multiple orders.

[0051] Preferably, the storage and retrieval system of the procurement / replenishment system further comprises a stock database comprising data of at least one attribute of one or more items.

[0052] To increase the efficiency of processing storage boxes or storage containers through the inventory handling station assembly, the at least one box-lifting device includes a first box-lifting device and a second box-lifting device, and the control system is configured to instruct the conveyor system to transport containers to the first box-lifting device or the second box-lifting device depending on the occupancy of the first box-lifting device and the second box-lifting device. More preferably, the occupancy of the first box-lifting device and the second box-lifting device is determined by one or more sensors within the first box-lifting device and the second box-lifting device. For example, the one or more sensors may be photoelectric sensors (through-beam sensors, reflective sensors, or proximity sensors) that transmit and receive light. In response to signals from the one or more sensors within the box-lifting device, the control system can determine the occupancy of the box-lifting device and, if necessary, redirect the storage box or storage container to the second box-lifting device to provide some slack in the buffer zone. This may be through a change in the orientation of the storage box or storage container in the buffer zone.

[0053] The present invention also provides a method of fulfilling a plurality of orders with the procurement / replenishment system of the present invention, each of the plurality of orders comprising one or more items, the method comprising: i) grouping or matching a plurality of orders comprising one or more items based on the plurality of orders having at least one attribute common to each of the plurality of orders; ii) identifying a first container comprising one or more items having at least one attribute common to each of the plurality of orders; iii) commanding one or more baggage handling devices to retrieve a first container storing one or more items from the grid framework structure; and iv) lowering the first container via at least one vertical chute to a feeding zone. v) transporting the first container to an access station; vi) transferring one or more items from the first container to a plurality of delivery containers associated with a plurality of orders; vii) transporting the first container to a buffer zone; viii) lifting the first container towards the grid; ix) instructing one or more baggage handling devices operable on the grid to retrieve the first container from the buffer zone and return the first container to the grid framework structure; A method comprising:

[0054] When an order for one or more items is received, or when it is otherwise desired to retrieve items needed to fully or partially fulfill an order, a control system associated with the inventory handling station assembly of the present invention can request the retrieval of any storage bins or containers containing the desired items to be retrieved at the access station functioning as a retrieval station to the inventory handling station assembly. Such storage bins or containers can be lifted by overhead baggage handling devices operable on the grid and delivered to a port, where they can be retrieved from one or more stacks within the corresponding portion of the grid framework structure and delivered to the inventory handling station assembly by being lowered below a delivery column of the grid framework structure. At least one chute in the supply zone is configured to cooperate with the delivery column to receive the storage bins. Similarly, at least one box lifting device is configured to cooperate with the retrieval column to raise the storage bins or containers to a level where they will be retrieved by the baggage handling device, thereby exiting the buffer zone.

[0055] The multiple orders can comprise a first order of one or more items and a second order of one or more items. The first bin or storage container comprises one or more items having common or shared attributes between the first order and the second order. The method includes: i) identifying a second container comprising one or more items having at least one attribute common to each of the plurality of orders; ii) instructing one or more baggage handling devices to retrieve a second container storing one or more items from the grid framework structure; iii) lowering the second container via at least one vertical chute into the feeding zone; iv) transporting the second container to the access station; v) transferring one or more items from the second container to a plurality of delivery containers associated with a plurality of orders; vi) transporting the second container to the buffer zone; vii) lifting the second container towards the grid; viii) instructing one or more load handling devices operable on the grid to retrieve the second container from the buffer zone and return the second container to the grid framework structure; Further provided are:

[0056] Preferably, the delivery container or box is a bag. The method further comprises transferring one or more items from the one or more containers to the one or more bags. Optionally, the one or more bags comprising the fulfilled order of one or more items are transported to one or more electronically controllable lockers where the bags are stored in one or more compartments for retrieval by a customer or a courier.

[0057] Another aspect of the present invention is a method of stocking or replenishing one or more items with a procurement / replenishment system according to the present invention, comprising: i) transferring a stock of one or more items to one or more receptacles in an access station; ii) moving one or more containers containing a stock of one or more items into the buffer zone; iii) lifting one or more containers containing a stock of one or more items towards a grid within the buffer zone; iv) commanding one or more cargo handling devices to retrieve one or more containers containing a stock of one or more items from the buffer zone and transport the one or more containers to the grid framework structure; A method comprising:

[0058] In this aspect of the invention, the access station of the inventory handling station assembly of the present invention doubles as a replenishment station. Palletized items or other batches of items arrive at the replenishment station. For example, a pallet may be removed from a truck and moved to the inventory handling station assembly, which doubles as a stock station or replenishment station. Upon removal or unpacking of any packaging, one or more items are transferred to one or more storage bins or storage containers within the access station. Depending on the type of item, as discussed above, each of the one or more items is classified with a specific SKU, or stock keeping unit. As commonly known in the art, SKUs, or stock keeping units, are used by retailers to identify and track their inventory or stock. An SKU is a unique code consisting of letters and numbers that identifies characteristics about each item, such as manufacturer, brand, model, color, and size. This can be recorded in a barcode. Items of a particular type are grouped together according to the SKU. In one aspect of the invention, a package handling device operable on a grid framework structure is instructed to retrieve storage bins from upright columns within the grid framework structure. This may be an empty storage bin or container, or a partially empty storage bin or container storing items of the same type or with the same SKU as the palletized items. The method further comprises the steps of retrieving one or more containers from the grid framework structure, lowering the one or more containers via at least one vertical chute to a supply zone, and then commanding one or more load handling devices to transport the one or more containers from the supply zone to an access station that also serves as a stock station. In another aspect of the invention, fresh storage bins or containers can be introduced into the grid framework structure via the access station. In both cases, one or more items are loaded into the storage bin or container and fed into the grid framework structure via a buffer zone.Preferably, the method further comprises weighing one or more containers in the access station so that the weight of the storage box or container does not exceed a predetermined weight required to safely lift the storage box or container and / or the lifting device of the load handling device within the buffer zone. Typically, the lifting device of the load handling device, which comprises one or more motors, is rated to lift a predetermined weight above which the lifting device will struggle to lift the container. The weight of each storage box or container in the access station is measured by a weighing cell, for example, a load cell. Optionally, the conveyor system is instructed to prevent the storage box or container from being transported to the buffer zone if the weight of the storage box or container exceeds the predetermined weight.

[0059] Further features and aspects of the present invention will be apparent from the following detailed description of illustrative embodiments that proceeds with reference to the drawings. [Brief explanation of the drawings]

[0060] [Figure 1] 1 is a schematic diagram of a grid framework structure according to known systems; [Figure 2] Schematic of a top-down view showing a stack of boxes arranged within the framework structure of Figure 1. [Figure 3] 1 is a schematic diagram of a system of known baggage handling devices operating on a grid framework structure; [Figure 4] 1 is a schematic perspective view of a luggage handling device showing a lifting device gripping a container from above. [Figure 5] 5A is a schematic perspective cutaway view of the luggage handling device of FIG. 4, showing a container receiving space of the luggage handling device; and FIG. 5B is a schematic perspective cutaway view of the luggage handling device of FIG. 4, showing a container that fits into the container receiving space of the luggage handling device. [Figure 6] 1 is a front perspective view of an inventory handling station assembly according to one embodiment of the present invention; [Figure 7] FIG. 7 is a perspective view showing the framework of the inventory handling station assembly shown in FIG. 6; [Figure 8] FIG. 2 is a top view of a conveyor system according to one embodiment of the present invention. [Figure 9] FIG. 4 is a top view of a conveyor system according to another embodiment of the present invention. [Figure 10] 1 is a top plan view of a procurement center incorporating a mezzanine level to house inventory handling station assemblies, according to an embodiment of the present invention. [Figure 11] 4 is a flow chart illustrating the operational steps of the removal station, according to one embodiment of the present invention. [Figure 12] 4 is a flow chart illustrating the operational steps of a replenishment station, according to one embodiment of the present invention. [Figure 13] 1 is a block diagram illustrating components of a procurement system according to one embodiment of the present invention. [Figure 14a] 1 is a perspective view of an inventory handling station assembly incorporating a bagging station according to one embodiment of the present invention; [Figure 14b] FIG. 14B is a perspective view of the rear of the inventory handling station assembly shown in either FIG. 6 or FIG. 14A. [Figure 15] 1 is a flowchart illustrating the computational steps in matching or grouping multiple orders according to one embodiment of the present invention. [Figure 16] 1 is a perspective view of a storage box or container according to one embodiment of the present invention. [Figure 17] 1 is a perspective view of a storage box or container according to another embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0061] The present invention is conceived in contrast to known features of storage systems, such as the grid framework structure and baggage handling devices described above with reference to Figures 1-5. In a typical procurement center, a wide variety of items, such as grocery items, are stored in storage bins or containers, which are stored in one or more stacks within a grid framework structure, more specifically, within grid columns. A grid column is formed by a plurality of upright columns arranged as vertical storage locations. Individual containers may be stacked in vertical layers, and their location within the grid framework structure or "hive" may be indicated using coordinates in three dimensions to represent the location of the baggage handling device or container and the container depth (e.g., container at (X, Y, Z), depth W). Similarly, locations within the grid framework structure may be shown in two dimensions to represent the location of a baggage handling device or container and the container depth (e.g., container at (X,Y), depth Z). For example, Z=1 identifies the top layer of the grid framework structure, i.e., the layer immediately below the rail system, Z=2 is the second layer below the rail system, and so on down to the bottom layer, which is the lowest layer of the grid framework structure. The majority of grid columns within the grid framework structure are storage columns.

[0062] The order fulfillment system comprises a bin or container filling station, a storage and retrieval system, a plurality of order retrieval stations, an order container handling and sorting system, and dispatch equipment. Details of the order fulfillment system are described in PCT / IB2014 / 062165 (Ocado Innovation Limited), the details of which are incorporated herein by reference. In order fulfillment systems such as that described in PCT / IB2014 / 062165 (Ocado Innovation Limited), individual containers are stored within the storage and retrieval system and may contain one or more items, which may be identical. The storage and retrieval system comprises a grid framework structure in which storage bins or containers are stored within grid columns.

[0063] To retrieve an order comprising different items, it is often necessary to retrieve items from multiple source containers. Such containers can be retrieved from a storage and retrieval system and transported to a desired system for order retrieval. The specific container needed for order fulfillment is accessed by a robotic package handling device operable on a grid framework structure. The package handling device preferably includes a control unit that receives control signals from a control system wireless communication unit or central control system regarding information regarding where within the grid framework structure a storage bin or storage container should be retrieved and delivered. The control system controls the operation of one or more package handling devices operable on the grid framework structure and includes one or more processors, memory (e.g., read-only memory and random access memory), and a communication bus. The memory may be any storage device commonly known in the art, including, but not limited to, RAM, computer-readable media, magnetic storage media, optical storage media, or other electronic storage media used to store data and accessible by one or more processors.

[0064] At least one grid column is not used for storing containers and typically comprises a location where a load handling device can drop off and / or retrieve storage containers or storage bins to and from a retrieval or supply station external to the grid framework structure. In the art, such locations are typically referred to as "ports" and correspond to grid cells where storage bins or storage containers are dropped off or retrieved. Depending on whether the port is installed for the drop-off or retrieval of storage containers, the grid column on which the port is installed may be referred to as a "delivery column" installed at the drop-off port and a "recovery column" installed at the retrieval port.

[0065] As commonly known in the art, items in inventory are identified and tracked by unique codes called SKUs (Stock Keeping Units), which identify distinctive attributes for each item in inventory, such as manufacturer, brand, style, color, and size, and help distinguish different types of items in inventory or stock, such as a particular brand of cheese. When a retailer receives its stock of stock, it counts the amount of each SKU it has. Palletized items or other batches of items arrive at a bin filling or refill station. For example, a pallet of items may be removed from a truck or other transportation at an order processing / procurement center and moved to one or more storage bins or storage bin filling stations. Typically, a filling station includes a trolley, conveyor, trolley, etc. for holding multiple storage bins or storage bins. A filling station can accept either empty or partially filled storage bins. Once the desired stocking of a storage bin or storage bin is complete, the storage bin may be transferred, for example, by a conveyor, to storage within a storage and retrieval system where it is stored until needed to fulfill an order. For example, a storage box or storage container may be carried to a drop port by an overhead baggage handling device operable on a grid framework structure and lowered to a pick-up station where one or more of the items of the order can be picked up into a destination or delivery container.

[0066] The storage control and communication system is used to monitor inventory and track the location of each storage bin or storage container within the grid framework structure and the contents of each storage bin or storage container. The storage control and communication system may also form part of or communicate with a control system or central control system for controlling load handling devices instructed to retrieve a desired storage bin or storage container from within the grid framework structure and deliver it to a desired location or drop-off port on the grid framework structure at a desired time without conflict with other load handling devices operable on the grid framework structure.

[0067] In one embodiment of the present invention, the pick-up station doubles as a replenishment station. For purposes of this invention, a pick-up / replenishment station may be referred to as an inventory handling station assembly having an access station that can function as both a pick-up station and / or a replenishment station. The inventory handling station assembly cooperates with a storage and retrieval system to provide a fulfillment system for fulfilling one or more orders. In the embodiment shown in FIG. 6, the inventory handling station assembly 60 includes one or more chutes 62 that form a supply zone 64, an access station 66, and one or more box lifting devices 68 that form a buffer zone 70. By reference to that name, the one or more chutes 62 allow a load handling device operable on the grid framework structure 14b to lower a storage bin or container without assistance from the one or more chutes 62. This may be due to the effect of gravity when the storage bin or container is allowed to lower the chute 62 under its weight and / or is lowered by a lifting or winch mechanism of the load handling device.

[0068] One or more items are retrieved from or loaded into one or more storage bins or containers in the access station 66, depending on whether the access station 66 functions as a retrieval station or a replenishment station. The one or more chutes 62 and one or more box lifting devices 68 are arranged to cooperate with the grid framework structure 14b described above. The grid framework structure 14b comprises a plurality of upright columns in one or more vertical planes and arranged to form a plurality of vertical locations or vertical grid columns 15 for containers to be guided vertically by the upright columns. The plurality of vertical grid columns extends across the one or more chutes 62 and one or more box lifting devices 68 of the inventory handling station assembly 60 (see FIG. 6 ). The plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members moving transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces. The plurality of grid cells are sized to allow storage bins to enter or exit the grid cells. The plurality of grid cells include drop-off ports and removal ports, each positioned to cooperate with one or more chutes 62 and one or more bin lifting devices 68. More specifically, the grid columns in which the drop-off ports (delivery columns 15b) and removal ports (recovery columns 15c) are located are positioned to cooperate with one or more chutes 62 and one or more bin lifting devices 68 of the inventory handling station assembly 60, respectively.

[0069] The inventory handling station assembly 60 of the present invention can be deployed as a stand-alone station that can be easily retrofitted into an existing grid framework structure and thus can cooperate with grid running overhead. For example, at least one chute and at least one box lifting device can be aligned with one or more grid columns so that a storage container or storage box can easily pass through the grid column onto the at least one chute. Similarly, a storage box or storage container can be lifted from at least one box lifting device and passed through the grid column. The inventory handling station assembly 60 can be modular in structure, with the supply zone 64, access station 66, and buffer zone 70 being formed as modules that can be assembled together. As a result, the inventory handling station assembly 60 is not reliably connected to the grid framework structure but can be formed as a separate part of the grid framework structure. The versatility of the inventory handling station, which can be retrofitted into an existing grid framework structure, allows the inventory handling station assembly to be assembled in a variety of centers, from large distribution centers handling thousands of items to small convenience stores that cater to smaller percentage orders. For example, the stock handling station assembly may form part of a back-end setup where orders are filled at the back end before being dispatched to a customer or courier or at a storefront.

[0070] 6 and 7, the inventory handling station assembly 60 comprises a freestanding framework that divides the inventory handling station assembly into a supply zone 64, a buffer zone 70, and an access station 66. One or more chutes 62 in the supply zone 64 are receivable within the grid columns 15b and comprise at least two vertical guides 72 positioned to guide storage bins or containers through drop ports and into the supply zone 64 below the grid columns 15b. For purposes of definition, the grid columns in which the drop ports are located are referred to as delivery columns 15b. Similarly, the grid columns in which the removal ports are located are referred to as collection columns 15c. In a specific embodiment of the present invention, each of the one or more chutes 62 comprises four guides 72 receivable within the grid columns 15b of the grid framework structure 14b. Each of the guides 72 comprises two orthogonal plates (two container guide plates at right angles to each other) extending longitudinally along the length of the chute. 7, one end of each guide extends to and abuts against the grid column or delivery column 15b relative to the four upright columns that make up the grid column. Thus, a storage box or storage container lowered below the drop port is guided by the guide 72 through the delivery column 15b (on which the drop port is installed) to below the chute 62 in the supply zone 64.

[0071] Side walls or panels 74 are attached to the exterior of the at least two vertical guides 72 to surround the vertical chute 62. The side walls or paneling 74 provide a shield for an operator from one or more storage bins or containers descending down the chute 62 in the feeding zone 64. In the particular embodiment shown in FIG. 7, a first portion of the guide is covered by the side walls or panels 74, and a second portion of the guide is received within the delivery column 15b. This allows the side walls or panels 74 to provide a seamless transition from the delivery column 15b to the chute 62 of the inventory handling station assembly 60.

[0072] The conveyor system 76 transports storage bins or containers from the supply zone 64 to the access station 66 and then to the buffer zone 70, where the storage bins or containers are stacked vertically for removal by a load handling device operable on the grid framework structure 14b and return to either their original destination within the grid framework structure or a new destination within the grid framework structure. In a specific embodiment of the invention, the conveyor system 76 comprises multiple conveyor units, namely an entrance conveyor unit 78, at least one access conveyor unit 80, and an exit conveyor unit 82, arranged to transport the storage bins or containers from the supply zone 64 to the buffer zone 70 via the access station 66. The storage bins or containers are paused at the access station 66, which functions as a removal station or a replenishment station. The multiple conveyor units are arranged adjacent to or connected to one another so that the storage bins are transported from one conveyor unit to an adjacent conveyor unit as they travel along the conveyor system 76.

[0073] In an embodiment of the present invention, the entrance conveyor unit 78 is disposed within the feed zone 64, and more specifically, the entrance conveyor unit 78 is disposed within each of the one or more chutes 62. As shown in FIG. 7, the entrance conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 are on the same level. Similarly, the exit conveyor unit 82 is disposed within the buffer zone 70. Each conveyor unit may comprise any suitable arrangement of belts, chains, and / or rollers of a conveyor system well known in the art. In the specific embodiment of the present invention shown in FIG. 7, the entrance conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 comprise multiple roller conveyors for transporting storage bins or storage containers along a path on the conveyor system 76. The entrance conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 are disposed such that the path or transport direction of the storage bins or storage containers can follow a U-shaped path as shown in FIG. 8 or an L-shaped path as shown in FIG. 9. As shown in Figure 7, the conveyor system 76 is mounted on a roller frame. The entrance conveyor unit 78 and the exit conveyor unit 82 are positioned to accommodate a single storage bin above.

[0074] 8, the path or conveying direction of the entrance conveyor unit 78 may be parallel to and opposite to the path or conveying direction of the exit conveyor unit 82, such that the path or conveying direction of the at least one access conveyor unit 80 is perpendicular to or orthogonal to the path or conveying direction of both the entrance conveyor unit 78 and the exit conveyor unit 82. In other words, the storage bins or storage containers travel in a U-shaped path along the conveyor system 76, i.e., the storage bins change direction twice along the conveyor system. Optionally, as shown in FIG. 9, the path or conveying direction of the exit conveyor unit 82 extends longitudinally in the same conveying direction of the at least one access conveyor unit 80, i.e., the exit conveyor unit 82 is an extension of the at least one access conveyor unit 80. Here, the path or conveying direction of the entrance conveyor unit 78 is perpendicular to or orthogonal to the path or conveying direction of both the at least one access conveyor unit 80 and the exit conveyor unit 82, such that the storage bins or storage containers travel in an L-shaped path along the conveyor system 76, i.e., change direction once as the storage bins or storage containers travel from the supply zone to the buffer zone. In the specific embodiment of the invention shown in FIGS. 6 and 7, the conveyor system is arranged such that the path or conveying direction of the storage bins can follow both U-shaped and L-shaped paths along the conveyor system 76. The combination of U-shaped and L-shaped paths allows multiple storage bins or storage containers to be queued in the buffer zone 70 before being lifted towards the grid for subsequent retrieval by a load handling device operable on tracks or rails on the grid. This allows multiple storage bins or storage containers to be processed through the access station 66, compared to prior art solutions. The combination of U-shaped and L-shaped paths allows for a relatively narrow inventory handling station assembly for handling multiple storage bins or containers at the access station 66 compared to prior art solutions.

[0075] The at least one access conveyor unit 80 extends between the entrance conveyor unit 78 and the exit conveyor unit 82 and may comprise multiple conveyor units arranged adjacent to one another in a horizontal plane such that storage boxes or storage containers are transported along the access conveyor unit 80 from one conveyor unit to an adjacent conveyor unit. In the particular embodiment shown in FIGS. 6 and 7 , the at least one access conveyor unit 80 comprises six conveyor units. Alternatively, the at least one access conveyor unit 80 may be a single conveyor unit extending between the entrance conveyor unit 78 and the exit conveyor unit 80. Typically, at least one or more of the rollers of the access conveyor unit 80, and optionally the entrance conveyor unit 78 and / or the exit conveyor unit 82, will have integrated drive motors (not shown), and the remaining rollers may be connected to the drive rollers by belts (not shown) or may be passive.

[0076] An additional conveyor unit 84 (see FIGS. 8 and 9 ) positioned adjacent the entrance conveyor unit 78 and / or the exit conveyor unit 82 is integrated into at least one access conveyor unit 80. In a specific embodiment of the invention, the additional conveyor unit or direction-changing conveyor unit 84 comprises one or more rollers, belts, or chains disposed laterally or interdigitated between the rollers of the at least one access conveyor unit and arranged to be driven transversely to the conveying direction of the at least one access conveyor unit (see arrows in FIGS. 8 and 9 ). The additional conveyor unit or direction-changing conveyor unit 84 is lowered or raised by a lifting mechanism (not shown) relative to the rollers of the at least one access conveyor unit 80 so that, in the raised position, the direction-changing conveyor unit 84 contacts the storage box and causes the direction-changing conveyor unit 84 to pull or attract the storage box from the entrance conveyor unit 78 onto the at least one access conveyor unit 80. This is indicated by the arrows in FIGS. 8 and 9 . Once on the at least one access conveyor unit 80, the storage bin or conveyor can then be transported along the at least one access conveyor unit 80 through the access station 66 to the buffer zone 70. A similar setup is shown in the buffer zone 70, where a second direction-changing conveyor unit 84 is positioned to transport the storage bin or container onto an exit conveyor unit 82 within the buffer zone 70. While the specific embodiment describes a lifting mechanism that engages the direction-changing conveyor unit 84 with the storage bin on the entrance conveyor unit 78 and the exit conveyor unit 82, other direction-changing conveyor units commonly known in the art of conveyor systems, such as conveyor balls, rail-mounted trolleys, etc., are applicable to the present invention.

[0077] As shown in FIG. 6 , the access station 66 is above at least one access conveyor unit 80 and comprises a work surface 86 having an opening 88 that allows an operator to gain access to a storage bin or storage container on the at least one access conveyor unit 80 below. As discussed above, the operator can retrieve or supply desired items to or from a storage bin in the access station 66 depending on whether the access station 66 functions as a retrieval station or a replenishment station. If the at least one access conveyor unit 80 comprises multiple conveyor units, an access conveyor unit 90 (indicated by light shading in FIGS. 8 and 9 ) positioned below the opening 88 in the work surface 86 comprises a weigh cell, or the weigh cell can be positionable anywhere along the at least one access conveyor unit 80. The weigh cell is connected to the at least one access conveyor unit 80 and is positioned to weigh the storage bin in the access station 66. The weigh cell may be a load cell or any other weigh cell commonly known in the art. A control panel (not shown) at the front of the access station 66 displays the weight of the storage bin as items are removed from or loaded into it. For example, when operated as a pick station, a weigh cell measures the weight of the storage bin or container as one or more items are removed from the storage bin. The storage control and communication system discussed above is used to monitor the inventory or stock of specific items by recording the weight of the storage bin as items are removed from the storage bin. This allows the storage control and communication system to track the contents of each storage bin or container stored within the grid framework structure. When the contents of a particular storage bin or container with a particular attribute or SKU are running low, as measured by the weigh cell and recorded by the storage control and communication system, a notification is sent to an operator, for example, via the control panel, to restock the storage bin.

[0078] When operated as a replenishment or supply station, fresh stock is loaded into storage bins in the access station 66 before being transported to and stored in the grid framework structure until needed to fulfill an order. The storage bins or storage containers may be carried to a drop port by an overhead baggage handling device operable on the grid framework structure 14b and lowered to the inventory handling station assembly 60, where one or more of the items can be loaded into the storage bins or storage containers at the access station 66. The storage bins or storage containers are weighed at the access station 66 each time an item is loaded into the storage bin. The scales prevent the storage bins from being overloaded in the access station 66, such that the box lifting devices and / or lifting mechanisms of the baggage handling devices in the buffer zone 70 may be prevented from being able to lift the storage bins or storage containers. The lifting mechanisms of the baggage handling devices and / or the motors of the box lifting devices are rated to carry a predetermined weight. Once the predetermined weight is reached, a display on the control panel provides notification to the operator, i.e., via the display panel, that the weight of the particular storage box or storage container has been reached and no further items can be added to the storage box before it is transported to the buffer zone 70. Additionally or alternatively, the lifting mechanism of one or more of the box lifting devices may include a weighing cell that weighs the storage box or storage container as it is lifted towards the grid framework structure 14b.

[0079] To prevent one or more storage boxes or storage containers from getting stuck at the access station 66, the buffer zone 70 includes one or more box lifting devices 68 to allow one or more storage boxes to be stacked vertically within the buffer zone 70. The box lifting device 68 includes a lifting arm and a lifting mechanism. In a specific embodiment of the present invention, the box lifting device 68 includes a pair of lifting arms 92, i.e., two lifting arms 92. The space between the lifting arms 92 is wide enough to allow the exit conveyor unit 82 to pass between the lifting arms 92 as it descends past the exit conveyor unit 82. In use, the lifting arms 92 are lowered to a lowest level below the exit conveyor unit 82 so that the lifting arms 92 can engage the bottom wall of a storage box on the exit conveyor unit. The storage box or storage container is lifted from its lowest position on the exit conveyor unit 82 to its highest position toward the grid framework structure 14b, such that the storage box is vertically spaced from the exit conveyor unit 82. This allows a second storage bin or container to enter the exit conveyor unit 82 and be stacked vertically below the storage bin or container above it. The highest storage bin waits until a baggage handling device operable on the grid at an upper level can retrieve it through a removal port via retrieval column 15c. More specifically, a gripping device of the baggage handling device can grasp the storage bin or container at the highest level and lift it into the container receiving space of the baggage handling device. A sensor detects the retrieval of the storage bin at the highest level, which causes a lifting arm 92 to lower below the second storage bin or container resting on the exit conveyor unit 82 and then signals a control system or controller to be lifted to the highest level, allowing a third storage bin or container queued in the buffer zone to enter the buffer zone 70 via the exit conveyor unit 82.Once the storage box or container enters buffer zone 70, the entire process is repeated.

[0080] The box lifting devices 68 may include multiple pairs of lifting arms 92 that are vertically spaced apart to allow multiple storage bins to be stacked vertically at different heights within the buffer zone 70. For example, a first pair of lifting arms may be positioned to lift a first storage bin to a first height, a second pair of lifting arms may be positioned to lift a second storage bin to a second height, and so on. This allows multiple storage bins to be stacked vertically at different heights within the buffer zone 70. In addition, one or more box lifting devices 68 may be positioned adjacent to each other. To conserve space and reduce the footprint of the inventory handling station assembly 60, a first box lifting device may be positioned at an end of at least one access conveyor unit 80 so that a storage bin or storage container can be transported to the first box lifting device along the same path of the access conveyor unit 80. If the first box-lifting device is fully occupied, the storage box can be instructed to change direction to an adjacent second box-lifting device, for example, in a direction perpendicular to the conveying direction of the at least one access conveyor unit. This can be achieved by controlling a direction-changing conveyor unit 84 adjacent to the buffer zone 70 to convey the storage box to the second box-lifting device. Here, the control system or a separate controller monitors the occupancy of the first and second box-lifting devices and, depending on the occupancy, determines whether to convey the storage box to the first or second box-lifting device. Occupancy of the box-lifting device 68 is determined by one or more sensors to detect the presence of a storage box or storage container within the box-lifting device. Examples of sensors include, but are not limited to, proximity sensors such as optical sensors.

[0081] Having multiple box lifting devices 68 allows for greater throughput of storage bins or storage containers through the inventory handling station assembly 60. In both cases, the storage bins follow either a U-shaped path or an L-shaped path from the access station 66 depending on whether the first or second box lifting device is occupied. The number of box lifting devices 68 is not limited to two, and the exit conveyor unit 82 can be arranged to allow for multiple box lifting devices 68 to be at the receiving end of at least one access conveyor unit 80.

[0082] Similar to the one or more chutes 62 in the supply zone 64, the one or more box lifting devices 68 include at least two guides 94 that guide the storage box or container vertically for lifting by the lifting arms 92. In the particular embodiment shown in FIG. 7, four guides 94 are shown, with a portion of the highest guide received within the grid column or collection column 15c where the removal port is located. Similarly, a bracket 96 can be used to connect the highest portion of the box lifting device 68 to the collection column 15c of the grid framework structure 14b (see FIG. 7). The bracket 96 includes a guide that guides the storage box or container into the collection column. This allows the box lifting device 68 to be a separate part of the grid framework structure described above—and thus, to be retrofitted into an existing grid framework structure. The one or more box lifting devices 68 include a side wall or panel 74 attached to the exterior of at least a portion of the guide to enclose the box lifting device 68 and prevent components of the box lifting device 68 from being exposed to the lifting arms 92.

[0083] In a known procurement or distribution center 100 shown in FIG. 10 , items and stock required to fulfill customer orders are placed in bins or storage bins 10. One or more storage bins or storage bins 10 are stacked in a grid column 15a (first grid column). The grid columns vary in height depending on the number of storage bins or storage bins stacked in the grid column. The known procurement center also includes various other stations, including, but not limited to, a charging station for charging rechargeable batteries that power the baggage handling devices on the grid and a service station for performing routine maintenance on the baggage handling devices. A separate area 102 is provided adjacent to the grid framework structure 14 to accommodate any one or combination of the stations. Typically, the separate area 102 is provided by incorporating a mezzanine level 104 supported by vertical beams between adjacent grid framework structures 14 and is generally a freestanding structure. The mezzanine level 104 provides a tunnel, for example, to accommodate a pick-up station and / or any one of the stations described above. FIG. 10 shows grid framework structures 14 on either side of the tunnel created by the mezzanine 104 suitable for accommodating the inventory handling station assembly of the present invention. Grids 22 from adjacent grid framework structures extend across the top of the mezzanine 104 to connect to the grids 22 on either side of the mezzanine 104. The inventory handling station assembly is installed below the grid columns 15b, 15c (second grid columns) that extend across the top of the mezzanine 104 so that the grid columns 15b, 15c cooperate with one or more vertical chutes 62 in the supply zone 64 and one or more box lifting devices 68 in the buffer zone 70. As is apparent from FIG. 10, the grid columns 15b, 15c at the top of the mezzanine 104 are shallower than the grid columns 15a on either side of the mezzanine 104, i.e., they can accommodate only one or two layers of containers in a stack. As also shown in FIG. 10, the mezzanine is supported by separate vertical beams.The vertical beams supporting the mezzanine floor abut against the grid framework structure 14 on either side of the mezzanine floor.

[0084] One or more package handling devices 30 are operable on the grid or grid structure 14. Package handling device 30 preferably includes a control unit that receives control signals from a wireless communication unit of the control system or a central control system regarding information regarding where to retrieve and deliver containers or totes within the grid framework structure. For purposes of the present invention, the grid framework structure, one or more package handling devices operable on the grid framework structure, and a control system for controlling operation of the package handling devices on the grid framework structure form a storage and retrieval system. The storage and retrieval system and inventory handling station assembly form part of a procurement / replenishment system.

[0085] FIG. 11 is a flowchart 105 illustrating the steps by which the access station 66 of the inventory handling station assembly 60 operates as a pick station. At the pick station, a storage bin or container is lifted by the baggage handling device 30 from a stack containing inventory items needed to fulfill a customer order. Once lifted by the baggage handling device 30, the storage bin or container is delivered by the baggage handling device to a drop port 106, which is commanded by the control system to lower the storage bin or container down a chute 62 to a supply zone 108. At the supply zone 64, the storage bin is transported by the conveyor system 76, where it is paused at the access station 66, which also serves as a pick station 110. At the pick station, one or more needed inventory items may be manually or robotically removed from the storage bin or container and placed in a delivery container 112, which forms part of the customer order, and filled for shipment at the appropriate time. The picking process is repeated 114 until the items needed to fulfill the order are completed. Once the pick stage is completed, the storage container is transported to a buffer zone where the storage containers are stacked vertically 116. As discussed above, depending on the occupancy of one or more box lifting devices, the storage container or storage container is lifted to its highest position where it waits to be retrieved by a load handling device operable on a grid or grid structure 118. The entire process shown in Figure 11 is repeated as more storage containers or storage containers are lowered into the inventory handling station assembly to fulfill multiple orders of one or more items.

[0086] The access station 66 of the inventory handling station assembly 60 can also double as a decanting or refilling station where palletized items or other batches of items of a particular characteristic SKU arrive at the inventory handling station assembly and are loaded into storage bins or storage containers. FIG. 12 is a flowchart 119 illustrating steps for refilling storage bins or storage containers with inventory or items. Storage bins or storage containers needing replenishment with one or more items can be retrieved from storage within the grid framework structure and delivered to the inventory handling station assembly via one or more chutes within the supply zone 120. Alternatively or additionally, empty storage bins or storage containers can be added at the access station and then added to the storage and retrieval system. At the access station, items of the characteristic SKU are loaded into storage bins or storage containers 122. The identification of the item's characteristic SKU and storage bin is stored in an inventory database accessible by the control system or storage control and communication system (see FIG. 13). Decanting or loading of containers at the access station continues until completion 124. At the access station, weigh cells or load cells measure the weight of the storage bin or container on at least one access conveyor unit as items are loaded into the storage bin or container 125. Steps 124 and 125 occur in unison, i.e., simultaneously, as items are transferred to the storage bin or container. As discussed above, the weigh cells are used to determine whether the storage bin or container has reached a predetermined weight that would exceed the safe lifting capacity of the lifting mechanism and / or box lifting device 126 of the load handling device. Once the required amount of items has been loaded into the storage bin or container and the weight of the storage bin or container is below or equal to the predetermined weight, at least one conveyor unit is enabled to move to a buffer zone where the items are queued before being retrieved by a load handling device operable on the grid structure 128, 130.However, if the weight of the storage bin or container exceeds the predetermined weight, the operator removes one or more items from the storage bin or container until the weight of the storage bin or container reaches the desired weight or falls below the predetermined weight 127. The entire process of refilling the storage bin or container is repeated with different items or SKUs.

[0087] FIG. 13 is a block diagram of components of a procurement system 132 according to one embodiment of the present invention. The procurement system components shown in FIG. 13 are applicable whether the access station is a retrieval station and / or a replenishment station. Operation of the baggage handling devices 30 on the grid is controlled by a control system or controller 134, which includes one or more processors 136, memory (e.g., read-only memory and random access memory) 140, and a communication bus 138. The control system 134 is communicatively coupled to one or more baggage handling devices 30 operating on the grid via a communication network over wireless transmitters / receivers (not shown). The communication network may be, for example, a local area network (LAN), a wide area network (WAN), or any other type of network. In certain embodiments, the baggage handling devices preferably include a control unit that receives control signals from a wireless communication unit of the control system. The one or more processors of the control system can execute instructions stored in ROM and / or RAM to control the movement of one or more baggage handling devices operating on the grid. The control system 134 is also communicatively coupled to the inventory handling station assembly 60. Control system 134 receives signals associated with the weight of the storage bins or storage containers within the access stations. Control system 134 may also control conveyor system 76 and / or box lifting devices 68 to control the movement of the storage bins or storage containers as they are processed through access stations 66 and / or queued within buffer zone 70. As commonly known in the art, one or more sensors, e.g., position sensors or proximity sensors, are distributed along the path of conveyor system 76 and used to monitor the position of the storage bins or storage containers at different stages along conveyor system 76, e.g., different zones within the inventory handling station (feed zone, access station, and buffer zone).A user interface (not shown) communicatively coupled to the control system 134 is provided at the access station to authorize the removal or loading of one or more items into or from a storage bin or storage container. For example, an operator authorizes an ordered item to be removed from a storage bin and placed in a delivery container by the user interface (not shown). The user interface signals the control system 134 that the ordered item has been picked up. This is repeated until all of the ordered items have been picked up. The weight of the storage bin or storage container can be correlated with the identification of the storage bin or storage container. The identification can also correspond to the type of item or SKU of the item stored in the storage bin or storage container. To identify each storage bin or storage container, preferably, each storage bin or storage container includes a label (e.g., an electronic label) readable by the user interface to establish the identity of each storage bin or storage container. Optionally, the label can include a barcode, a 1D barcode, a 2D barcode, a QR code, or an RFID tag. The user interface may be push button or a graphical user interface (GUI). The identification of the bin or container is correlated with the contents of the bin or container by its distinctive attribute or SKU.

[0088] Data associated with one or more orders is stored in the order database 142. Each order stored in the order database 142 includes one or more items requested by one or more customers. Each item in an order can be characterized by different attributes. As discussed above, the attributes may be SKUs, commonly known in the art, that characterize an item, such as manufacturer, brand, model, color, and / or size. Data associated with inventory or stock in the storage and retrieval system is stored in the inventory database 144. The data includes attributes of the items characterized by their corresponding SKUs stored in each bin or storage container, and the location of the bin or storage container within a grid framework structure. The location of the bin or storage container within the grid framework structure may be represented by three-dimensional Cartesian coordinates to represent the container location and container depth (e.g., bin in (X, Y, Z), depth W). Optionally, the control system 134 can correlate one or more items in an order with corresponding attributes of items stored in the inventory database 144.

[0089] The order database 142 is dynamically updated as more orders are received. Similarly, the inventory database 144 is dynamically updated each time stock is added to or removed from a bin or storage container. Each time an order for one or more items is placed, the control system 134 accesses the inventory database 144 to determine whether any one of the items is available, the quantity of the item in the inventory database 144, and the location of one or more bins or storage containers to fulfill the order within the storage retrieval system, i.e., grid framework structure. Via one or more processors 136, the control system 134 instructs one or more package handling devices 30 to place and retrieve one or more bins or storage containers containing the associated items to fulfill the order.

[0090] Typically, delivery containers containing fulfilled orders are transported via conveyors, forklifts, or other means to loading vehicles for shipment to any ordering customers. At a fulfillment facility, packaged containers associated with one or more assembled orders may be sorted and delivered to a vehicle, such as a truck, for delivery to the customer. While such a process is appropriate when the timescale for fulfilling and shipping an order generally spans a one- or multiple-day period, such a process is not ideal when an order needs to be fulfilled and shipped over a period of one or more hours or less, such as immediate shipping. Immediate shipping is increasingly popular for procuring convenience grocery items, i.e., staple grocery items, such as milk, cheese, or bread. Here, such orders are either picked up and delivered to the customer or shipped in-store, from order receipt. Coupled with the rise of online shopping, this has led to a plethora of different e-commerce models for purchasing goods online for immediate shipping. These range from click-and-collect models, where customers who purchase or select items online can pick them up either in-store or at a central collection location of their choice, or at a home delivery service where the items are delivered directly to the customer's premises. To provide for immediate dispatch of orders, the procurement system can be adapted to include a bagging station where the delivery container comprises one or more bags.

[0091] FIG. 14 illustrates a bagging station 146 adjacent to the inventory handling station assembly 60 of the present invention, where one or more items fulfilling an order are packaged into one or more bags 148. The bagging station 146 can be positioned near the access station 66 so that items retrieved from one or more storage bins or containers in the access station 66 can be transferred to one or more bags 148 at the bagging station 146. Retrieval can be performed manually by hand or by a robot as taught in GB2524383 (Ocado Innovation Limited). The one or more bags 148 at the bagging station 146 are separated or held in different compartments or spaces within the bagging station by one or more partitions 150. The one or more bags 148 are supported on an elevated surface (e.g., table 152) that is divided into separate compartments by the partitions 150. Each of the partitions 150 can represent an individual order or a portion of an order.

[0092] The bagging station 146 allows a small number of items, typically convenience items, to be immediately packaged into one or more bags 148 from the access station 66 before being dispatched to the customer. The process of picking up an order via a pick-up station described above with reference to FIG. 11 still applies. The storage and retrieval system can be made on a smaller scale to accommodate requests for smaller groups of items, typically staple or convenience items, such as bread, eggs, milk, etc. An operator at the bagging station 146 acknowledges via a user interface that one or more items are being picked up and transferred to a bag. Bags with the picked order can be shipped directly to the customer at the storefront rather than processed through a delivery facility. Alternatively, with the growth of click-and-collect offerings, bags with the picked order can be deposited in an electronically controlled locker for subsequent collection by the customer or courier. Multiple partitions 150 at the bagging station 146 allow multiple orders to be picked for immediate dispatch. Each of the compartments provided by partition 150 includes a user interface 154 for authorizing the removal of ordered items from a storage bin or container.

[0093] More particularly, at least one chute includes at least one input device, more specifically, a reader, e.g., a primary and / or matrix barcode reader, to identify the identity of the storage bin or container as the baggage handling device lowers the storage bin or container into the supply zone. One or more storage bins include a label readable by the at least one input device to establish the identity and contents of each of the one or more storage bins as they progress down the at least one chute. The label on one or more of the storage bins may be a barcode, 1D barcode, 2D barcode, or QR code or RFID tag. FIG. 14b shows a rear view of the inventory handling station assembly 60 shown in either FIG. 6 or FIG. 14a of the present invention. In the specific embodiment shown in FIG. 14b, three chutes 62 are shown within the supply zone 64. Each of the chutes 62 includes a reader or scanner 65 that scans the label on the storage bin or container as it pauses on the entrance conveyor unit. The signal from the reader 65 is used by the control system to identify the storage box or container and its contents within the inventory handling station assembly.

[0094] To ensure that the package handling device is instructed to retrieve the appropriate storage bin or storage container to the inventory handling station assembly 60, the signal from the reader 65 can also ensure that the storage bin or storage container delivered by the package handling device correlates with the identification of the storage bin or storage container within the inventory handling station assembly 60, e.g., providing an electronic handshake between the inventory handling station assembly 60 and the package handling device instructed to deliver the storage bin or storage container. Typically, the position or location of each storage bin or storage container within the grid framework structure is stored in an inventory database. When a package handling device is instructed to retrieve a storage bin or storage container to fulfill an order, the package handling device is instructed to move to a location on the grid where the desired storage bin or storage container will be located. The storage bin or storage container is then transported to the inventory handling station assembly. The identification of the storage bin or storage container is read by the reader 65 at the supply zone. This is compared to the identification of the storage bin or storage container instructed by the package handling device to see if they correlate to ensure the appropriate storage bin or storage container is delivered to the inventory handling station assembly 60. To fulfill an order, the control system, via one or more processors, instructs one or more package handling devices operable on the grid to retrieve one or more storage bins or storage containers containing the related items from the storage and retrieval system. In some cases, the package handling devices may have to repeatedly retrieve the same storage bin or storage container throughout the day to fulfill multiple orders requesting the same item. This is particularly exacerbated when the item is a common convenience or staple item, such as milk, cheese, or bread. In another aspect of the present invention, the control system 134, in communication with the order database 142 and / or the inventory database 144, is instructed by one or more processors to match or group multiple orders that share a common item type or SKU.When one or more types of items in each of the orders are shared or common among the multiple orders, the multiple orders are grouped or matched to increase the efficiency of procuring the multiple orders, thereby enabling the procurement system to meet criteria for immediate shipment. An organization unit stored in memory organizes the orders so that the multiple orders share one or more common items. The process of matching or grouping multiple orders based on at least one item of the multiple orders being common among the multiple orders can be described by a flowchart 160 shown in FIG. 15. In a first step, a control system accesses data associated with the multiple orders in an order database 162. Via one or more processors, the control system compares a first order of one or more items with a second order of one or more items to determine whether there are one or more items in common between the first order and the second order 164. If one or more items are common between the first order and the second order 166, the control system matches or groups the first order with the second order 168. If there are no common items, the control system revisits the order database to look for other orders that have common items, otherwise the control system proceeds to process the order as described above with reference to FIG. 11.

[0095] Once the order is matched, the control system, via one or more processors, places a bin or container with the contents of the bin or container storing the associated item, and then accesses an inventory database 170 172 to retrieve the item. As discussed above, the inventory database includes data associated with the listed items and their characteristic attributes or SKUs, along with the location of the bin or container storing the item. The sequence of step 168 of matching the first order with the second order and step 170 of accessing the inventory database is not limited to that shown in FIG. 15 and can be interchanged. At the access station, the contents of the bin or container are shared between the first order and the second order. Sharing bins or containers between multiple orders increases the fulfillment system's ability to fulfill multiple orders. Generally, common items between multiple orders are more prominent if the orders contain convenience or key items.

[0096] In a further improvement to increasing the efficiency of the procurement system, one or more storage bins or containers 10b, 10c can store two or more different items or SKUs 176a, 176b, as shown in Figures 16 and 17. The different items can be separated within the storage bin or container by a distributor 174. Here, the control system matches multiple orders that share common items. For example, an algorithm identifies multiple items that are frequently requested together, i.e., analyzes the frequency distribution of items ordered. These typically include convenience items or staple, common everyday items with relatively short sell-by dates, such as milk and dairy products. One or more storage bins or containers 10b, 10c can be organized within the storage and retrieval system, such that each of the one or more storage bins or containers can store different items that are frequently ordered together, i.e., have a high frequency distribution of requests. Groups of orders can be matched or grouped together based on the group of items that are common or shared among each of the orders. By grouping or matching multiple orders in which multiple different items are common among the orders and retrieving a single storage bin or container to store the different items, the contents of the single storage bin or container can be shared among multiple delivery containers, such as bags, associated with the multiple orders. Thus, in addition to retrieving separate storage bins or containers for each item in the multiple orders, the control system can install and retrieve a storage bin whose contents can be shared among the multiple orders. This not only increases the efficiency of fulfilling multiple orders, but also dramatically reduces the number of storage bins or containers that need to be retrieved to fulfill an order, since the control system is not separately required to retrieve a storage bin or container for each item in each individual order. Fulfillment efficiency is increased, and a greater number of different items or SKUs can be stored within a given storage bin, as shown in FIG. 17.

[0097] Storing different items in one or more storage bins or containers, such that each of the one or more storage bins or containers stores a plurality of different items as shown in Figures 16 or 17, similarly increases the likelihood that the contents of any one of the storing storage bins or containers can be shared among multiple delivery containers, e.g., bags, associated with multiple orders. For example, a storage bin or container may include one or more items having a distinctive first attribute or SKU and one or more items having a distinctive second attribute or SKU, and the storage bin or container, or more specifically, the delivery container associated with multiple orders, may have one or more items of the first attribute or second attribute that can be shared among the multiple orders.

[0098] Table 1 is a hypothetical example of a group of five orders. Each of the labeled orders, i.e., orders 1, 2, 3, 4, and 5, comprises an order of five different items or SKUs with characteristic attributes labeled A, B, C, D, E, and F. Here, orders 1, 2, 3, and 5 share the same requested item B. Orders 1, 3, and 5 also share the same requested item D, i.e., common items B and D. To increase the efficiency of sourcing the five orders, when sourcing orders 1, 2, 3, and 5, the control system matches or groups orders 1, 2, 3, and 5 such that a single storage bin or container storing item B can be retrieved, whose contents are shareable among orders 1, 2, 3, and 5. This is further increased if a single storage bin or container stores items of both types B and D, such that the contents of the single storage bin or container are shareable among orders 1, 3, and 5. This greatly speeds up the fulfillment of the five orders, as fewer storage boxes or containers need to be repeatedly retrieved from the storage and retrieval system (grid framework structure) to fulfill multiple orders.

[0099] [Table 1] The inventions described in the original claims of this application are set forth below. [1] An inventory handling station assembly 60 for a storage and retrieval system, said storage and retrieval system comprising: a plurality of upright columns 16 in one or more vertical planes and arranged to form a plurality of grid columns 15 for stacking one or more containers 10 between the upright columns 16 and being guided vertically by the upright columns 16, the plurality of upright columns 16 being interconnected at their upper ends by a first set of grid members 18 extending in a first direction and a second set of grid members 20 extending in a second direction, the second set of grid members 20 moving transversely to the first set of grid members 18 in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; a grid framework structure 14 comprising: the first set of grid members 18 and the second set of grid members 20 respectively support a first set of tracks 22a and a second set of tracks 22b for a load handling device 30 to move one or more containers 10 on the grid framework structure 14 at an upper level of the grid framework structure 14; wherein the inventory handling station assembly 60 is i) a feeding zone 64 comprising at least one vertical chute 62 configurable to cooperate with at least one upright column 16, said at least one vertical chute 62 having a first opening for receiving a container 10 lowered by at least one baggage handling device 30 through a grid cell, and a second opening for allowing said container 10 to exit said feeding zone 64; ii) a buffer zone 70 for vertically stacking one or more containers 10 with at least one box lifting device 68, said at least one box lifting device 68 being positionable to lift a container 10 upwards towards said grid so that, in use, said container 10 can be retrieved by said at least one load handling device 30; iii) an access station 66 intermediate the feeding zone 64 and the buffer zone 70 to provide access to one or more containers 10 exiting the feeding zone 64; iv) a conveyor system 76 configured to transport one or more containers 10 from the supply zone 64 to the buffer zone 70 via the access station 66; An inventory handling station assembly 60 comprising: [2] The conveyor system 76 comprises an entrance conveyor unit 78, an exit conveyor unit 82, and at least one access conveyor unit 80, wherein: the entrance conveyor unit (78) is disposed within the supply zone (64) and is arranged to convey containers (10) in a first conveying direction from the second opening of the at least one vertical chute (62) to the at least one access conveyor unit (80); the exit conveyor unit 82 is disposed within the buffer zone 70 and is arranged to convey containers 10 from the at least one access conveyor unit 80 to the buffer zone 70 in a second conveying direction; [1] The inventory handling station assembly 60, wherein the at least one access conveyor unit 80 is arranged to transport containers 10 from the supply zone 64 to the buffer zone 70 via the access station 66 in a third conveying direction. [3] The inventory handling station assembly 60 of [2], wherein the entrance conveyor unit 78 and the exit conveyor unit 82 are arranged such that the first conveying direction of the entrance conveyor unit 78 is opposite and parallel to the second conveying direction of the exit conveyor unit 82, and wherein the third conveying direction of the at least one access conveyor unit 80 is perpendicular to both the first conveying direction of the entrance conveyor unit 78 and the second conveying direction of the exit conveyor unit 82. [4] The inventory handling station assembly 60 of [2], wherein the conveyor system 76 is positioned such that the first conveying direction of the entrance conveyor unit 78 is perpendicular to both the second conveying direction of the exit conveyor unit 82 and the third conveying direction of the at least one access conveyor unit 80. [5] The inventory handling station assembly 60 of any one of [2] to [4], wherein the at least one access conveyor unit 80 is equipped with a load cell for weighing containers. [6] The inventory handling station assembly 60 of [4], wherein the at least one access conveyor unit 80 comprises a plurality of adjacent conveyor units arranged to transport containers 10 horizontally from the supply zone 64 to the buffer zone 70 via the access station 66. [7] The inventory handling station assembly (60) of [6], wherein each of the plurality of conveyor units is arranged to accommodate a single container (10). [8] The inventory handling station assembly 60 of [6] or [7], wherein at least one of the plurality of conveyor units comprises the load cell. [9] The inventory handling station assembly 60 of [8], comprising a work surface 86 positioned above the at least one access conveyor unit 80, the work surface 86 having an opening that allows access to the containers 10 on the at least one of the plurality of conveyor units.

[10] An inventory handling station assembly 60 as described in any one of [1] to [9], wherein the at least one box lifting device 68 comprises two parallel arms 92 engageable with the bottom wall of the container 10 and a lifting mechanism arranged to move the two parallel arms 92 vertically from a lowest level below the conveyor system 76 to a highest level above the conveyor system 76.

[11] The inventory handling station assembly (60) of

[10] , wherein the two parallel arms (92) are spaced apart a distance greater than a width of the exit conveyor unit (82).

[12] An inventory handling station assembly 60 as described in any one of [1] to

[11] , wherein the at least one vertical chute 62 has at least two vertical guides 72 for guiding a container 10 vertically along the at least one vertical chute 62, and each of the at least two vertical guides 72 is receivable within a grid column 15.

[13] The inventory handling station assembly 60 of

[12] , wherein each of the at least two vertical guides 72 of the at least one vertical chute 62 comprises two orthogonal plates extending along the length of the at least one vertical chute 62.

[14] The inventory handling station assembly (60) of

[12] or

[13] , further comprising a sidewall (74) surrounding the at least one vertical chute (62).

[15] A) A storage and retrieval system comprising a grid framework structure 14, said grid framework structure 14 comprising: a) a plurality of upright columns 16 in one or more vertical planes, arranged to form a plurality of grid columns 15 for one or more containers 10 to be stacked between and vertically guided by the upright columns 16; the plurality of upright columns 16 are interconnected at their upper ends by a first set 18 of grid members extending in a first direction and a second set 20 of grid members extending in a second direction, the second set 20 of grid members moving transversely to the first set 18 of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; the first set of grid members 18 and the second set of grid members 20 respectively support a first set of tracks 22a and a second set of tracks 22b for a load handling device 30 to move one or more containers 10 on the grid framework structure 14 at an upper level of the grid framework structure 14; b) one or more containers 10, each of said one or more containers 10 comprising one or more items characterized by attributes; c) one or more luggage handling devices 30 remotely operated to move the one or more containers 10 stored within the grid framework structure 14, each of the one or more luggage handling devices 30 i) a wheel assembly for guiding the luggage handling device 30 on the grid; ii) a container receiving space 40 located above the grid; iii) a lifting device arranged to lift a single container 10 from the stack 12 into said container-receiving space 40; Equipped with Equipped with B) A procurement / replenishment system comprising an inventory handling station assembly 60 as described in any one of [1] to

[14] and the one or more luggage handling devices 30, which are remotely operated to move the one or more containers 10 stored in the grid framework structure 14 to and / or from the inventory handling station assembly 60.

[16] The procurement / replenishment system of

[15] , wherein the plurality of grid columns (15) comprises a first set of grid columns and a second set of grid columns, wherein the first set of grid columns is arranged to store one or more containers (10) in a stack (12), and wherein the inventory handling station assembly (60) is arranged below the second set of grid columns such that, in use, a baggage handling device (30) operable on an upper level of the grid framework structure (14) can lower a container (10) through the at least one grid column (15) and down the at least one vertical chute (62), and the at least one box lifting device (68) is arranged below at least one grid column (15) such that the at least one vertical chute (62) and the at least one box lifting device (68) are operable to lift a container (10) to be removed through the at least one grid column (15) and into the container receiving space (40) of the baggage handling device (30).

[17] The procurement / replenishment system of

[16] , wherein the second set of grid columns is supported by a mezzanine floor 104.

[18] The procurement / replenishment system of

[16] or

[17] , wherein the second set of grid columns comprises at least one delivery column 15b and at least one return column 15c, the at least one chute 62 being positioned below the at least one delivery column 15b, and the at least one box lifting device 68 being positioned below the at least one return column 15c.

[19] The procurement / replenishment system of any of

[16] to

[18] , further comprising a bagging station 146, the bagging station 146 comprising a table having a surface for supporting one or more bags 148 and at least one user interface 154 in communication with a bagging station control system.

[20] The procurement / replenishment system described in

[19] , wherein the table is divided into one or more spaces by one or more partitions 150, and each of the one or more spaces has at least one user interface 154.

[21] The procurement / replenishment system of

[19] or

[20] , further comprising a plurality of electronically controllable lockers, each of the plurality of electronically controllable lockers comprising a compartment sized to accommodate the one or more bags 148.

[22] When the storage and retrieval system is executed by one or more processors 136 in response to receiving a plurality of orders, the one or more processors 136 may be configured to: i) grouping or matching the plurality of orders based on at least one attribute of the one or more items being common among the plurality of orders; ii) generating a signal instructing the luggage handling device 30 to retrieve a first container storing the one or more items common to the plurality of orders; iii) generating a signal instructing the luggage handling device 30 to lower the first container through the at least one grid column 15 and down the at least one vertical chute 62; iv) instructing the conveyor system 76 to convey the first container to the access station 66 such that the one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders; v) instructing the conveyor system 76 to convey the first container to the buffer zone 70; The procurement / replenishment system of any one of

[16] to

[21] further comprises a control system 134 having a memory 140 for storing instructions.

[23] The control system 134 may instruct the one or more processors 136 to: v) generating a signal instructing the luggage handling device 30 to retrieve a second container storing the one or more items common to the plurality of orders; vi) generating a signal instructing the luggage handling device 30 to lower the second container through the at least one grid column 15 and down the at least one vertical chute 62; vii) instructing the conveyor system 76 to convey the second container to the access station 66 such that the one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders; viii) commanding the conveyor system 76 to convey the second container to the buffer zone 70;

[22] The procurement / replenishment system according to

[22] , further configured to cause instructions to be executed.

[24] The procurement / replenishment system of

[23] , wherein the control system 134 is further configured to cause the one or more processors 136 to execute instructions to generate signals instructing the one or more baggage handling devices 30 to retrieve the first container and / or the second container from the buffer zone 70 via the at least one grid column 15.

[25] A procurement / replenishment system as described in any one of

[22] to

[24] , wherein the first container comprises one or more items of a first attribute and one or more items of a second attribute, and wherein the one or more items of the first attribute and / or the one or more items of the second attribute are common among the multiple orders.

[26] The storage and retrieval system further comprises an order database 142 comprising data associated with a plurality of orders for one or more items;

[22] to

[25] , wherein the control system 134 is configured to access the order database 142 to group or match the multiple orders based on at least one attribute of the one or more items being common among the multiple orders.

[27] The procurement / replenishment system of

[26] , wherein the storage and retrieval system further comprises an inventory database 144 comprising data on at least one attribute of one or more items.

[28] The procurement / replenishment system of any one of

[22] to

[27] , wherein the control system 134 is further instructed to record the weight of one or more containers in the access station 66.

[29] The procurement / replenishment system of any one of

[19] to

[28] , wherein the at least one box lifting device 68 comprises a first box lifting device and a second box lifting device, and the control system 134 is configured to instruct the conveyor system 76 to transport the container 10 to the first box lifting device or the second box lifting device depending on occupancy of the first box lifting device and the second box lifting device.

[30] The procurement / replenishment system of

[29] , wherein the occupancy of the first box lifting device and the second box lifting device is determined by one or more sensors within the first box lifting device and the second box lifting device.

[31] A method of fulfilling a plurality of orders by the procurement / replenishment system of any one of

[22] to

[30] , wherein each of the plurality of orders comprises one or more items, the method comprising: i) grouping or matching the plurality of orders comprising one or more items based on the plurality of orders having at least one attribute common to each of the plurality of orders; ii) identifying a first container comprising the one or more items having at least one attribute common to each of the plurality of orders; iii) instructing one or more luggage handling devices 30 to retrieve said first container storing said one or more items from the grid framework structure 14; iv) lowering the first container via one or more vertical chutes 62 into a feeding zone 64; v) transporting the first container to an access station 66; vi) transferring the one or more items from the first container to a plurality of delivery containers associated with the plurality of orders; vii) transporting the first container to a buffer zone 70; viii) lifting the first container towards a grid; ix) instructing the one or more baggage handling devices 30 operable on the grid to retrieve the first container from the buffer zone 70 and return the first container to the grid framework structure 14; A method comprising:

[32] i) identifying a second container comprising the one or more items having at least one of the attributes common to each of the plurality of orders; ii) instructing the one or more luggage handling devices 30 to retrieve the second container storing the one or more items from the grid framework structure 14; iii) lowering the second container via the at least one vertical chute 62 into the feeding zone 64; iv) transporting the second container to the access station 66; v) transferring the one or more items from the second container to the plurality of delivery containers associated with the plurality of orders; vi) transporting the second container to the buffer zone 70; vii) lifting the second container towards the grid; viii) instructing the one or more baggage handling devices 30 operable on the grid to retrieve the second container from the buffer zone 70 and return the second container to the grid framework structure 14; The method of

[31] further comprising:

[33] The method of

[31] or

[32] , wherein the first delivery container and / or the second delivery container is a bag.

[34] The method according to any one of

[31] to

[33] , further comprising the step of transporting the one or more bags to one or more electronically controllable lockers.

[35] The method according to any one of

[31] to

[34] , further comprising the step of weighing one or more containers in the access station 66.

Claims

1. A) A storage and retrieval system comprising a grid framework structure, said grid framework structure comprising: a) a plurality of upright columns in one or more vertical planes arranged to form a plurality of grid columns for stacking one or more containers between the upright columns and being guided vertically by the upright columns; the plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members extending transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces; the first set of grid members and the second set of grid members respectively support a first set of tracks and a second set of tracks for a load handling device to move one or more containers on the grid framework structure at an upper level of the grid framework structure; b) one or more containers, each of said one or more containers comprising one or more items characterized by attributes; c) one or more luggage handling devices remotely operated to move the one or more containers stored within the grid framework structure; and each of the one or more luggage handling devices: i) a wheel assembly for guiding said luggage handling device over said grid; ii) a container receiving space located above the grid; iii) a lifting device arranged to lift a single container from the stack into said container-receiving space; Equipped with Equipped with B) an inventory handling station assembly and the one or more load handling devices are remotely operated to move the one or more containers stored in the grid framework structure to and / or from the inventory handling station assembly; the inventory handling station assembly: i) a feeding zone comprising at least one vertical chute configurable to cooperate with at least one upright column, said at least one vertical chute having a first opening for receiving a container lowered by at least one baggage handling device through a grid cell, and a second opening for allowing said container to exit said feeding zone; ii) a buffer zone for vertically stacking one or more containers comprising at least one box lifting device, said at least one box lifting device being positionable to lift a container upwards towards said grid so that, in use, said container can be retrieved by said at least one cargo handling device; iii) an access station intermediate the feeding zone and the buffer zone to allow access to one or more containers exiting the feeding zone; iv) a conveyor system configured to transport one or more containers from the supply zone to the buffer zone via the access station; Equipped with C) a bagging station, the bagging station comprising a table having a surface for supporting one or more bags and at least one user interface in communication with a bagging station control system, the table being divided into one or more spaces by one or more partitions, each of the one or more spaces comprising the at least one user interface.

2. A procurement / replenishment system as described in claim 1, wherein at least one access conveyor unit of the inventory handling station assembly is equipped with a load cell for weighing containers.

3. A procurement / replenishment system as described in claim 1 or 2, wherein at least one access conveyor unit of the inventory handling station assembly comprises a plurality of adjacent conveyor units arranged to transport containers horizontally from the supply zone to the buffer zone through the access station.

4. A procurement / replenishment system as described in claim 3, wherein each of the multiple conveyor units of the inventory handling station assembly is arranged to accommodate a single container.

5. A procurement / replenishment system as described in claim 4, further comprising a work surface of the inventory handling station assembly positioned above at least one access conveyor unit, the work surface having an opening allowing access to containers on at least one of the plurality of conveyor units.

6. 6. The procurement / replenishment system of claim 1, wherein the plurality of grid columns comprises a first set of grid columns and a second set of grid columns, wherein the first set of grid columns is arranged to store one or more containers in a stack, and wherein the inventory handling station assembly is arranged below the second set of grid columns such that, in use, a baggage handling device operable on an upper level of the grid framework structure can lower a container through the at least one grid column and down the at least one vertical chute, and the at least one box lifting device is operable to lift a container to be removed through the at least one grid column and into the container receiving space of the baggage handling device.

7. The procurement / replenishment system of claim 6 , wherein the second set of grid columns is supported by a mezzanine level.

8. 8. The procurement / replenishment system of claim 6 or 7, wherein the second set of grid columns comprises at least one delivery column and at least one return column, at least one chute positioned below the at least one delivery column, and the at least one box lifting device positioned below the at least one return column.

9. 9. The procurement / replenishment system of claim 1, further comprising a plurality of electronically controllable lockers, each of the plurality of electronically controllable lockers comprising a compartment sized to accommodate the one or more bags.

10. The storage and retrieval system, when executed by one or more processors and in response to receiving a plurality of orders, includes instructing the one or more processors to: i) grouping or matching the plurality of orders based on at least one attribute of the one or more items being common among the plurality of orders; ii) generating a signal instructing the luggage handling device to retrieve a first container storing the one or more items common to the plurality of orders; iii) generating a signal instructing the luggage handling device to lower the first container through the at least one grid column and down the at least one vertical chute; iv) instructing a conveyor system to convey the first container to the access station such that the one or more items common to the plurality of orders can be transferred into a plurality of bags associated with the plurality of orders; v) instructing the conveyor system to convey the first container to the buffer zone. The procurement / replenishment system of claim 1 , further comprising a control system comprising: a memory for storing instructions.

11. The control system may cause the one or more processors to: v) generating a signal instructing the luggage handling device to retrieve a second container storing the one or more items common to the plurality of orders; vi) generating a signal instructing the luggage handling device to lower the second container through the at least one grid column and down the at least one vertical chute; vii) instructing the conveyor system to convey the second container to the access station such that the one or more items common to the plurality of orders can be transferred to a plurality of bags associated with the plurality of orders; viii) instructing the conveyor system to convey the second container to the buffer zone. The procurement / replenishment system of claim 10 , further configured to cause instructions to be executed.

12. 12. The procurement / replenishment system of claim 11, wherein the control system is further configured to cause the one or more processors to execute instructions that generate signals instructing the one or more baggage handling devices to retrieve the first container and / or the second container from the buffer zone via the at least one grid column.

13. 13. The procurement / replenishment system of claim 10, wherein the first container comprises one or more items of a first attribute and one or more items of a second attribute, and wherein the one or more items of the first attribute and / or the one or more items of the second attribute are common among the multiple orders.

14. the storage and retrieval system further comprising an order database comprising data associated with a plurality of orders for one or more items; 14. The procurement / replenishment system of claim 10, wherein the control system is configured to access the order database to group or match the multiple orders based on at least one attribute of the one or more items being common among the multiple orders.

15. The procurement / replenishment system of claim 14 , wherein the storage and retrieval system further comprises an inventory database comprising data for at least one attribute of one or more items.

16. The procurement / replenishment system of claim 10 , wherein the control system is further instructed to record a weight of one or more containers in the access station.

17. 17. The procurement / replenishment system of claim 10, wherein the at least one box lifting device comprises a first box lifting device and a second box lifting device, and the control system is configured to instruct the conveyor system to transport a container to the first box lifting device or the second box lifting device depending on occupancy of the first box lifting device and the second box lifting device.

18. 18. A method of fulfilling a plurality of orders by a procurement / replenishment system according to any one of claims 10 to 17, wherein each of the plurality of orders comprises one or more items, the method comprising: i) grouping or matching the plurality of orders comprising one or more items based on the plurality of orders having at least one attribute common to each of the plurality of orders; ii) identifying a first container comprising the one or more items having at least one attribute common to each of the plurality of orders; iii) instructing one or more baggage handling devices to retrieve the first container storing the one or more items from a grid framework structure; iv) lowering the first container into a feeding zone via one or more vertical chutes; v) transporting the first container to an access station; vi) transferring the one or more items from the first container to a plurality of bags associated with the plurality of orders; vii) transporting the first container to a buffer zone; viii) lifting the first container towards a grid; ix) instructing the one or more baggage handling devices operable on the grid to retrieve the first container from the buffer zone and return the first container to the grid framework structure; A method comprising:

19. i) identifying a second container comprising the one or more items having at least one of the attributes common to each of the plurality of orders; ii) instructing the one or more luggage handling devices to retrieve the second container storing the one or more items from the grid framework structure; iii) lowering the second container through the at least one vertical chute into the feeding zone; iv) transporting the second container to the access station; v) transferring the one or more items from the second container to the plurality of bags associated with the plurality of orders; vi) conveying the second container to the buffer zone; vii) lifting the second container towards the grid; viii) instructing the one or more baggage handling devices operable on the grid to retrieve the second container from the buffer zone and return the second container to the grid framework structure; 20. The method of claim 18, further comprising:

20. 20. The method of claim 18 or 19, further comprising transporting the one or more bags to one or more electronically controllable lockers.

Images