Systems and methods for order processing

Abstract

To provide improvement in storing and taking-out of a storage and delivery container in an order processing system.SOLUTION: A system that manages a shipping container includes a storing and taking-out system and a processor. The storing and taking-out system includes a structural framework, a plurality of robotic load handlers and a rail. The processor is configured to: generate a signal for commanding or controlling the plurality of robotic load handlers; take out the container containing a stored article from the storing and taking-out system; generate a signal for commanding or controlling delivery to an order picking station; and generate a signal for commanding or controlling the plurality of robotic load handlers to store the shipping container containing a picked article.SELECTED DRAWING: Figure 2

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]

[0001] This application claims priority to UK Patent Application No. 1310784.2 filed on June 17, 2013, which is incorporated herein by reference in its entirety.

[0002]

[0002] The disclosure herein relates to automated order fulfillment systems. In particular, the disclosure provides improved systems and methods for handling or manipulating containers in fully or semi-automated storage and retrieval systems.

[0003]

[0003] Various forms of both fully and semi-automated order processing and fulfillment systems are known, and these, and the various components they comprise, may take many forms.

[0004]

[0004] In some forms of cargo-to-human picking systems, receptacles or other containers containing, for example, inventory and / or other items, may be stored within and retrieved from the storage and retrieval system to facilitate picking of items from containers at picking stations. Items picked from storage containers may be placed in shipping containers. The shipping containers are often of a different type than those used to store the items, and are provided by a system or other source external to the storage system.

[0005]

[0005] An order assembled for delivery often consists of multiple shipping containers. Once the individual containers are properly filled with picked items, they are typically set aside in a separate order sortation or handling system until all shipping containers required for the order, or an entire delivery vehicle, are ready. At that time, the multiple containers required to fulfill the order are assembled and provided to a shipping facility for loading or delivery.

[0006]

[0006] Following delivery, the empty shipping containers are returned to a sorting or dispatch area and fed back into another order sorting and handling system for reuse. In other embodiments, the shipping containers may be in the form of non-returnable cartons.

[0007]

[0007] While the use of separate order sorting and handling systems works well for relatively small facilities, for example, handling up to a few thousand container picks per hour and either relatively few customer orders per hour or relatively few items per customer order, this can become more of a problem in larger systems with tens of thousands or more container picks per hour and hundreds or thousands of customer orders, each containing dozens of different items, requiring extensive conveyor systems for transporting and sorting the order containers.

[0008]

[0008] For this and other reasons, there is considerable room for improvement in the efficiency of order processing systems and their components, including storage and retrieval systems and handling of storage and shipping containers. Summary of the Invention

[0009]

[0009] Automated and semi-automated cargo storage and retrieval systems, various aspects of which may be referred to as "order fulfillment," "storage and retrieval," and / or "order picking" systems, may be realized in a wide variety of types and forms. One method of providing access to stored cargo for automated and / or semi-automated retrieval includes, for example, placing the cargo, which may be of any desired type, into receptacles or other containers (hereinafter generally referred to as containers), and then stacking and / or otherwise arranging the containers vertically in layers, optionally in multiple columns and / or rows, or in a racking system, such that individual containers are accessible, in whole or in part, by the automated container retrieval system. Such systems may include, for example, various combinations of containers; container stacking support mechanisms, which may include mechanical devices such as framed and / or freestanding, stackable, and / or otherwise specialized containers; and automated or semi-automated (i.e., "robotic") retrieval devices, such as load handlers, which may operate using wheels, on grids, on racking, or other forms of rails, and / or on other forms of moving mechanical devices.

[0010]

[0010] Upon receiving a customer order for multiple items stored in the storage and retrieval system, an automated or semi-automated container handler retrieves storage containers containing the associated items from a grid, racking, or other ordered arrangement of storage containers and delivers them to an automated or semi-automated picking station where the items are removed from the storage containers and placed in a shipping container, typically along with other items.

[0011]

[0011] The present invention, in some instances, provides various improvements in the storage and handling of storage and shipping containers within such order fulfillment systems.

[0012]

[0012] In various aspects, for example, the present invention provides a method of operating an order fulfillment system that includes a cargo storage and retrieval system. The cargo storage and retrieval system includes a grid, racking, or other ordered arrangement of containers. Such a method includes storing separate sets of containers within the grid or other ordered arrangement, the separate sets configured to store items within the grid or racking and to deliver the items to customers who have ordered the items. By storing both types of containers within the grid or racking, significant efficiencies can be realized in a number of ways, including, for example, more efficient use of floor space, faster and more efficient handling or manipulation of containers by robotic load handlers, and fewer moving parts, which may result in less investment and lower operating costs compared to prior art systems.

[0013]

[0013] In some embodiments and aspects of the invention, further efficiencies may be realized by storing one or more shipping containers in a storage container, with the storage container containing items for use in fulfilling a customer order, and storing such combined container sets in a storage and retrieval grid, racking, or other customized arrangement.

[0014]

[0014] In accordance with a further aspect of the invention, efficiencies may be realized by using a single type of container for both storing and delivering items within the storage and retrieval system. Suitable containers are preferably strong and sturdy enough for both handling by the storage and retrieval system and any other components of the order fulfillment system, and for transport, delivery, etc., and are also preferably light enough for efficient transport and delivery.

[0015]

[0015] In a further aspect, the invention provides storage containers that are specifically configured to facilitate the storage and rapid and efficient removal of shipping containers. For example, such storage containers may include holes or other openings or structural features that allow an automated container handling device to quickly lift or otherwise remove filled or empty shipping containers from the storage container in which they were previously located.

[0016]

[0016] In various further aspects, the disclosure provides corresponding systems and devices for implementing such systems, devices and methods, providing logical structures such as a set of coded instructions executable by a machine.

[0017]

[0017] According to an aspect of the present disclosure, there is provided a system for managing shipping containers, the system including a storage and retrieval system and at least one processor, the storage and retrieval system including a structural framework defining a grid of storage locations configured to receive a plurality of containers, a plurality of robotic load handlers for retrieving containers from any one of the storage locations, and at least one rail positioned about the grid to enable access to each of the storage locations by at least one of the plurality of robotic load handlers. The at least one processor is configured to generate signals to instruct or control at least one of the plurality of robotic load handlers to store a storage container containing the stored item in the storage and retrieval system; generate signals to instruct or control at least one of the plurality of robotic load handlers to retrieve at least one container containing the stored item from the storage and retrieval system and deliver the retrieved at least one container to an order picking station; and generate signals to instruct or control at least one of the plurality of robotic load handlers to store at least one shipping container containing the at least one picked item in the storage and retrieval system.

[0018]

[0018] In some examples, each of the at least one shipping container is stored in a storage container for storage in at least one of the storage locations.

[0019]

[0019] In some examples, the at least one processor is configured to generate a signal to instruct or control at least one of the plurality of robotic load handlers to store a fully or partially picked shipping container in the storage and retrieval system.

[0020]

[0020] According to an aspect of the present disclosure, a method of operating an order fulfillment system including a cargo storage and retrieval system is provided, the method including: storing, using at least one robotic load handler, a plurality of storage containers including stored items in at least one of a plurality of storage locations in the storage and retrieval system; storing, using the at least one robotic load handler, a plurality of shipping containers in at least one of a plurality of adjacent stacks; and retrieving, using the at least one robotic load handler, a plurality of containers including at least one of the shipping containers from at least one of the plurality of storage locations and delivering the retrieved container to an order picking station. [Brief explanation of the drawings]

[0021]

[0021] The present invention is illustrated in the figures of the accompanying drawings, which are meant to be illustrative and not limiting, and in which like references are intended to refer to similar or corresponding parts. [Figure 1]

[0022] FIG. 1 is a schematic flow diagram illustrating an embodiment of a process and system according to the present invention. [Figure 2] FIG. 2 is a schematic flow diagram illustrating an embodiment of a process and system according to the present invention. [Figure 3]

[0023] FIG. 3 is a schematic diagram of systems and devices suitable for use in implementing embodiments of the present invention. [Figure 4] FIG. 4 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 5]FIG. 5 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 6]

[0024] FIG. 6 is a schematic diagram of a container suitable for use in implementing embodiments of the present invention. [Figure 7] FIG. 7 is a schematic flow diagram illustrating aspects of a process and system according to the present invention. [Figure 8] FIG. 8 is a schematic diagram of a container suitable for use in implementing aspects of the present invention. [Figure 9]

[0025] FIG. 9 is a schematic diagram of systems and devices suitable for use in implementing embodiments of the present invention. [Figure 10] FIG. 10 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 11] FIG. 11 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 12] FIG. 12 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 13] FIG. 13 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 14] FIG. 14 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 15] FIG. 15 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 16] FIG. 16 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 17] FIG. 17 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 18] FIG. 18 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 19] FIG. 19 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 20] FIG. 20 is a schematic diagram of systems and devices suitable for use in implementing aspects of the present invention. [Figure 21]

[0026] FIG. 21 is a flow diagram illustrating an exemplary method embodiment. Description of the embodiment

[0022]

[0027] Preferred embodiments of methods, systems and apparatus suitable for use in implementing the present invention will now be described with reference to the figures.

[0023]

[0028] One of the most important applications of a storage and retrieval system according to the present invention is in the fully or semi-automated processing of orders, for example through use as component 2 of an automated order processing or fulfillment system 100, as shown in FIG.

[0024]

[0029] 1, an order fulfillment system 1000 includes a bin or container filling station 1, a storage and retrieval system 2, 400, a plurality of order picking stations 4, an order container handling and sortation system 5, and a shipping facility 3. As will be appreciated by those skilled in the relevant art, the various components of such a system 1000 can be configured in any of a wide variety of ways using many different types of devices and processes in various combinations. Furthermore, such systems and processes may be used for sorting, storing, and delivering any type of merchandise, including, for example, groceries and / or other office, household, or consumer goods.

[0025]

[0030] Although various aspects of the process and system are illustrated in FIG. 1 using separate functional or schematic boxes, it will be understood by those skilled in the relevant art that in various embodiments, the physical, logical, and other aspects of the illustrated system 1000 and functions can be combined or otherwise shared in a wide variety of configurations.

[0026]

[0031] The container filling or restocking station 1 and associated processes may provide any aspect of the order processing system 1000 that enables incoming pallets and / or other multipacks of items to be separated and placed, individually or in groups, into separate containers 10 for storage in a grid-based, rack-based, or other type of storage and retrieval system 400. Such processes may be performed using any appropriately configured automated or semi-automated system, for example, using various types of conveyors, trolleys, robotic devices, etc., and / or may be performed manually by workers. In various embodiments, the restocking station 1 may include single or multiple picking stations that pick and place one or more palletized, boxed, or otherwise packaged sets of items into initially empty or partially filled containers 10.

[0027]

[0032] The storage and retrieval (sub)system 400 may include any machine, device, infrastructure, or configuration suitable for fully or semi-automatically storing and retrieving containers 10 containing one or more items according to the disclosure herein. Such a system provides a means for storing such containers, for example, in a grid comprising multiple stacks, and a means for storing, retrieving, and / or otherwise accessing the containers stored in such stacks, as described herein, or by some other storage and retrieval means, such as a racking system serviced by a crane or shuttle.

[0028]

[0033] The order picking station 4 may include any type or form of system suitable for receiving containers 10 of items retrieved by the storage and retrieval system 400, allowing the items to be picked therefrom and placed into delivery containers 10, 80. Such systems 4 may include, for example, various types and forms of conveyor or trolley-based systems where the containers 10 may be loaded onto a conveyor or picking trolley for transport to a picking area and automated and / or manual unloading into a delivery or other order collection container 10, 80.

[0029]

[0034] The order container handling and sorting system 5 may include any type or form of system suitable for providing shipping containers 10, 80 to the order picking station 4 for filling with items required to complete an order, for holding, storing, and sorting containers intended to form part of an order, particularly an order requiring multiple containers to be filled, and for providing the containers 10, 80 constituting the order ready for delivery to the dispatch facility 3. At the dispatch facility 3, the containers 10, 80 may be loaded onto vehicles or otherwise prepared for dispatch.

[0030]

[0035] The shipping facility 3 may include any type or form of system suitable for receiving shipping containers 10, 80 from the order container handling and sorting system 5, suitable for providing a set of order containers for a vehicle or other delivery device, and suitable for receiving empty shipping containers 10, 80 following an order for delivery and returning the empty shipping containers 10, 80 to the order container handling and sorting system 5 for repacking at the order picking station 4.

[0031]

[0036] Aspects of the order processing or handling system 1000, including the storage and retrieval system 400, may be implemented using components provided by manufacturers such as Autostore, Cimcorp, Knapp OSR, Dematic Multishuttle, and the like.

[0032]

[0037] As previously noted, in various aspects, the invention provides various improvements in efficiency. For example, as shown in FIG. 2, the storage and other manipulation of both storage containers 10, 70 and shipping containers 10, 80 (see, e.g., FIGS. 6 and 8) within a storage and retrieval system 400 can reduce or even eliminate the need for a separate order container handling and sortation system 5, as well as the conveyor systems required to connect these separate systems.

[0033]

[0038] For example, in some embodiments, a unified storage and retrieval system may be implemented in which load handlers or other robots can access all parts of the storage and retrieval system (and thereby all storage and shipping containers) without the need for additional cranes and / or conveyors.

[0034]

[0039] In large picking systems, for example, large grocery picking systems, shipping container handling, transport, storage, and sorting systems may account for 25-35% of the equipment investment and take up up to 20-25% of the floor space. The present invention can reduce these numbers by 70-80% in some instances. Associated energy, maintenance, and spare parts costs may also fall by a similar percentage.

[0035]

[0040] 2, the storage and retrieval system 400 receives returned empty order containers 10, 80 directly from the shipping facility 3 and stores them at the order picking station 4 until they are required for the order picking process. Alternatively, the order containers may include cartons, bags, or the like that can be assembled or otherwise installed directly at the picking station.

[0036]

[0041] The order picking station 4 accepts both storage containers 10, 70 containing ordered items and empty and / or partially filled shipping containers 10, 80 from the storage and retrieval system 400, and returns both fully or partially emptied storage containers 10, 70 and order containers 10, 80 containing ordered, newly picked items to the storage and retrieval system 400. Individual order containers 10, 80 containing sufficient items ready for delivery may be held in the storage and retrieval system 400 until all such containers associated with an order are ready for dispatch.

[0037]

[0042] When all items required to fulfill an order, or a vehicle filled with an order, have been placed in one or more shipping containers 10, 80, the storage and retrieval system 400 can retrieve the shipping containers 10, 80 and provide them as a set to the shipping facility 3 for loading onto a delivery vehicle, etc., or otherwise processing them for delivery. In some examples, alternatively or additionally, shipping containers 10, 80 can be retrieved for shipping based on a shipping schedule to maintain workload at a shipping station or during periods of reduced activity of a robotic load handler.

[0038]

[0043] After all the contents of the storage container 10, 70 have been picked, the order picking station 4 can return the empty storage container 10, 70 to the storage and retrieval system 400 where it can be held until required by the filling station 1, at which time it can be returned by the storage and retrieval system 400 to the filling station 1 for refilling.

[0039]

[0044] Thus, by storing, otherwise handling, or manipulating both storage containers 10, 70 and order or shipping containers 10, 80, and by holding, sorting, and delivering sets of shipping containers corresponding to fulfilled orders to a shipping facility 3, the storage and retrieval system 400 can fulfill all of the container storage and handling processes previously provided by a separate order container handling and sortation system 5, and can reduce or eliminate the need for such a separate order container handling and sortation system 5, with corresponding improvements in efficient use of floor space and other facilities, including lighting, heating, air conditioning, mechanical maintenance, etc., as suggested, for example, by a comparison of Figures 1 and 2.

[0040]

[0045] Systems and methods according to the invention may, in some examples, be advantageously applied to the operation of any type of storage and retrieval system 400, including, for example, a grid of stacked containers 10. As shown for example in FIGS. 3-5 , such a system may include a grid 200 of containers 10 stored in rows 100 and columns 120 of a stack 30. A particular container 10 required for order fulfillment may be accessed by an automated device, such as a robotic overhead load handler 40, operating on rails 160 formed by a frame used to support the containers 10, thereby defining the grid 200. In some examples, the rails 160 may include a separate or independent structure that generates a path along which the load handler 40 can travel.

[0041]

[0046] The rails 160 along which the load handler 40 is configured to move may be referred to as a single or series of rods or elongated members. The rails may include a single rail, double rails, a track, a guideway, a groove, or any other structure along which the load handler 40 may operate.

[0042]

[0047] In any of the embodiments described herein, the storage and retrieval system 400 may include a rack structure serviced by a crane and / or shuttle system for storing the containers 10,70.

[0043]

[0048] As noted above, it is possible to configure the storage system in many different ways. For clarity and brevity, the following description focuses on one of these ways, namely, containers stacked on top of each other in a grid configuration. In embodiments with stacked storage containers 10, 70, discussed further below, it is advantageous for the storage containers 10, 70 to be strong enough to support stacking many containers high.

[0044]

[0049] An example of the operation of the system 1000 and related aspects of the invention will now be described with reference to Figures 2-5. At 1, a palletized or other batch of items arrives at a containerizing or restocking station. For example, at an order processing / fulfillment center, the palletized items may be unloaded from a truck or other means of transportation and cast into one or more containerizing stations 1, which may comprise tables, conveyors, trolleys, etc. for holding multiple bins or containers 10, 70. Upon removing or opening any packaging, one or more products or other items may be placed into the bins or other storage containers 10, 70.

[0045]

[0050] Upon completing the desired stock of containers 10, 70, the containers may be transferred, for example, by conveyor, for storage in the storage and retrieval system 400 and stored therein until needed for order fulfillment. For example, the containers 10, 70 may be brought to the port 70 and engaged by a mobile overhead load handler 40 or by a bottom access lifter / clamp (not shown) for storage within the stacks 30 of the grid 200 until needed for further order fulfillment processing.

[0046]

[0051] At the same time, or at any other desired time, one or more empty and / or partially filled order or shipping containers 10, 80 may be provided to the storage and retrieval system 400 and stored therein until needed at the order picking station 4 in preparation for an order. For example, using a conveyor, cart, or other device, one or more shipping containers 10, 80 may be brought to the same or another port 70 of the storage and retrieval system 400 and engaged by the same or another mobile overhead load handler 40 or by a bottom access lifter / clamp (not shown) for storage in the same or one or more other stacks 30 of the grid 200 until needed for further order fulfillment processing.

[0047]

[0052] Upon receiving an order for one or more items, or otherwise desiring to pick the items required to fulfill an order in whole or in part, a controller associated with an order picking station 4 may request the removal and delivery to such picking station of any storage containers 10, 70 containing the desired items and one or more shipping containers 10, 80. For example, such containers may be removed from one or more stacks 30 in the corresponding portion of the grid 200 of the storage and retrieval system 400 by being lifted by an overhead load handler 40, delivered to a port 70, and transported by conveyor to the desired picking station 4, and such containers may be delivered to the identified picking station 4.

[0048]

[0053] At picking station 4, the ordered items may be unloaded from any one or more suitable storage containers 10, 70 and placed into appropriate shipping containers 10, 80. When the shipping containers 10, 80 are properly filled with the ordered items, the shipping containers 10, 80 may be returned from picking station 4 to storage and retrieval system 400 until ready or otherwise required for delivery to shipping facility 3.

[0049]

[0054] For example, when an order requires items to be picked into multiple shipping containers 10, 80, the full or otherwise completed shipping containers 10, 80 may be returned by one or more load handlers 40 to one or more desired stacks 30 in the grid 200 for storage until all requested items have been picked into the shipping containers 10, 80. At that time, or at other scheduled or otherwise advantageous times, all shipping containers 10, 80 required for order fulfillment may be removed using one or more load handlers 40 and delivered via ports 70 and conveyors to the desired shipping facility 3 for loading onto one or more vehicles and delivery.

[0050]

[0055] As previously discussed, following delivery, the returned, empty or partially filled shipping containers 10, 80 may be returned by vehicle or other transport and may be returned to one or more desired stacks 30 of the grid 200 via conveyors, ports 70 and load handlers 40, etc.

[0051]

[0056] Containers 10 suitable for use in implementing various aspects of the invention may include any suitable bags, bins, boxes, baskets, pallets, and / or other containers.

[0052]

[0057] As will be appreciated by those skilled in the relevant art, the characteristics of suitable storage containers 10, 70 and shipping containers 10, 80 may depend, at least in part, on the nature of the order fulfillment system 1000, particularly the nature of the storage and retrieval system 400, order picking station 4, and shipping facility 3 used with the containers, as well as the nature of the items being stored and shipped, and the nature of the means by which the containers are shipped, e.g., truck, aircraft, refrigerated compartment, human document carrier, etc.

[0053]

[0058] For example, in a system 1000 comprising a grid-based automated storage and retrieval system 400, such as that shown in Figures 3-5, the storage containers 10, 70 tend to be relatively heavier, e.g., thicker-walled or larger gauge, and / or otherwise more robust, than the shipping containers 10, 80. For example, it is important for the shipping containers 10, 80 to be strong and durable enough to withstand extensive handling by the various components of the system 1000, yet light enough to be carried by human handlers and / or delivery personnel and to minimize transportation costs, which may depend at least in part on the weight of the load. Therefore, as will be appreciated by those skilled in the relevant art, it would be significantly advantageous to enable the system 1000, 400 to operate simply and efficiently with one or more types of storage containers 10, 70 and shipping containers 10, 80, respectively, using the systems and methods described herein.

[0054]

[0059] As previously noted, in embodiments of the invention that utilize container stacks 30, it is advantageous for the container 10 to be strong enough to support stacking many containers high. This can be achieved in any number of suitable ways, including, for example, using container walls of appropriate thickness and stiffness, and configuring the container 10 so that the walls of the stacked containers will successfully carry the stacked load. Integral and / or prefabricated stiffeners or reinforcements may also be advantageously used.

[0055]

[0060] As previously noted, in some situations, significant advantages may be realized by implementing the invention using a single type of container 10 for both storage and delivery of items within the storage and retrieval system 400. A suitable container 10 for such an embodiment is preferably strong and durable enough for both handling by the storage and retrieval system 400 and any other components 3, 4, 5, 6, etc. of the order processing system 1000, and for transportation, delivery, etc., yet is preferably light enough for efficient transportation and delivery.

[0056]

[0061] Thus, in various embodiments, the invention provides a method of operating an order fulfillment system (1000) comprising a cargo storage and retrieval system (400), the storage and retrieval system (400) comprising a grid (200) of storage locations for receiving containers (10), the method including storing a plurality of storage containers (10) containing stored items in the grid (200), retrieving one or more containers (10) from the grid (200) with items to be delivered as part of an order, unloading the items to be delivered as part of the order from one or more of the retrieved containers 10, placing the items in another container 10, and delivering the items from the container in which the items were placed to a customer delivery location.

[0057]

[0062] Another advantageous feature provided by the invention is the placement of one or more shipping containers 10, 80 within a storage container 10, 70 and the subsequent joint handling of the container combination 90 by a system 1000, 400, 4, 3, etc.

[0058]

[0063] For example, it is recognized that storage containers 10, 70, 80 require significant strength to allow for high stacking 30 of containers 10 within the storage and retrieval system 400. Providing such strength can add weight to the containers 10, 70, 80, which can limit the amount of payload available in vehicles used for distribution and restrict the human or mechanical ability to handle the containers. Furthermore, such containers 10, 70, 80 may not nest, which can make it difficult to handle multiple empty containers in a limited space, such as a vehicle. Finally, the use of heavy / strong containers 10, 70, etc. adds cost, which can be significant when a large number of order containers 10, 80 circulate in the distribution network 1000.

[0059]

[0064] Another aspect of the invention, therefore, employs, for example, the method described below of placing lighter, cheaper, and optionally nestable or collapsible order containers 10, 70 within storage vessels 10, 80. This allows for the storage and manipulation of order containers 10, 70 within a storage and retrieval system without sacrificing weight, cost, nestability, or collapsibility.

[0060]

[0065] For example, as shown in FIG. 6, shipping containers 10, 80 may be placed inside storage containers 10, 70 to form container combination 90. For such purposes, suitable configuration of shipping container 80 may allow container 80 to be stored within grid 200 and / or other form of storage and retrieval system 400, for example, by ensuring that top edge 81 of shipping container 80 does not protrude above top edge 71 of storage container 70 when placed therein, or otherwise allow container 80 to be handled by systems 1000, 400, 4, 3, etc. in the same manner as container 70, without requiring them to be constructed to the same stiffness, weight, strength, etc.

[0061]

[0066] One or more appropriately configured shipping containers 80 may be stored within a single storage container 70 to form a container combination 90. For example, as shown for example in FIG. 6, shipping containers 80 may be provided in a nestable configuration. In addition to allowing multiple shipping containers 80 to be stored within a single storage container 70, the use of a nestable shipping container configuration may facilitate easier and more efficient handling of shipping containers 80 in other ways; for example, it may be easier for human handlers to carry multiple shipping containers when they are nested, and / or it may be easier to transport nested shipping containers 80 in trucks and other means of transportation.

[0062]

[0067] Another means of storing multiple shipping containers 80 in a single storage container 70 is to use multiple types / sizes of shipping containers. For example, two, three, or more paper or other shopping bags or shipping boxes 80 may be stored in one or more shipping containers 80, and the shipping containers 80 containing the bags or boxes may be placed in the storage container 70 for further handling. Thus, using shopping bags or shipping boxes 80 in this manner can improve convenience for customers or other users when collecting and delivering orders, and thereafter.

[0063]

[0068] FIG. 7 illustrates the additional efficiencies made possible by placing shipping containers 10, 80 within storage containers 10, 70 into the resulting container combination 90, and the means by which they are achieved.

[0064]

[0069] As shown at 6 in FIG. 7 , one or more shipping containers 80 may be placed inside storage containers 70 at the shipping facility 3 or between the shipping facility 3 and the storage and retrieval system 400. For example, one or more shipping containers 80 may be placed inside each storage container 70, and optionally, one or more shopping bags or other bags may be placed inside such containers. The resulting container combination 90 may then be placed in grid 200 until needed at order picking station 4. At order picking station 4, the shipping containers in combination 90 may be stocked with items picked from the same container or storage containers 70, as described above, and the shipping containers in combination 90 may be further processed as described for order collection and delivery. When all shipping containers 80 associated with an order have been properly packed, and / or at a scheduled or otherwise desired time, the corresponding container combination 90 may be retrieved by system 400 and delivered to the shipping facility 3 or other desired location. At 5, the packed shipping containers 80 may be removed from combination 90 and loaded or otherwise processed for delivery. As will be appreciated by those skilled in the relevant art, the container 80, including the shopping bag 80, may be removed as a unit for further transportation or handling.

[0065]

[0070] Containers 10 suitable for use in practicing the invention may be equipped with any one or more of a wide range of specialized structural features to enable further advantages in handling efficiency.

[0066]

[0071] As one example, in some embodiments, it may be advantageous to provide cutouts, holes (openings), and / or other structural features 72 in storage containers 10, 70 to facilitate automated or semi-automated removal of shipping container 80 from storage container 70, as shown, for example, in FIG. 8. For example, a cutout, hole, or opening 72 in the bottom of storage container 70 may be used to allow a mechanical lifter or other device to push up through the bottom of container 70, thus facilitating easy removal of shipping container 80 by a human or other operator. As will be appreciated by those skilled in the relevant art, a wide variety of lugs, handles, and other structural features 72 may be provided for such purposes.

[0067]

[0072] In some examples, the shipping container 80 has one or more handles 88 that can be engaged by one or more mechanisms to place the shipping container in or remove it from the storage container 70. This mechanism may be used instead of, or in addition to, an opening-enabled mechanism or some other mechanism.

[0068]

[0073] For example, as shown in FIG. 8, the storage container 70 may include a cutout 78 extending below the level of the shipping container handle 88 to allow the handle to be engaged while the shipping container is being removed from or placed into the storage container.

[0069]

[0074] As previously noted, the principles of the invention may be applied, with particular advantage, to both semi-automated and / or fully automated order acceptance and fulfillment, including, for example, orders entered via the Internet and / or other public and private communications networks.

[0070]

[0075] As will be further appreciated by those skilled in the relevant art, significant advantages can be realized through full or partial automation of any of the processes described herein, or portions of the processes described. Some examples of such automation are provided in Figures 9 through 21.

[0071]

[0076] FIG. 9 shows one possible implementation of a machine for placing a shipping container 80 into a storage container 70 with the aid of a movable load handler 40. FIGS. 10-16 show the same configuration, with some elements removed for clarity. In this example, an empty but bagged shipping container 80 arrives at a transfer station 92 by conveyor. The movable load handler 40 places the storage container 70 on the transfer station 91, which can then be moved by conveyor 95 to a merge station conveyor 97. A transfer mechanism 93 lifts the shipping container 80 and moves it onto the merge station conveyor 97. The merge station conveyor 97, with the empty storage container 70, can then be raised by a lifting mechanism, releasing the shipping container 80 from the transfer mechanism 93. The combined shipping and storage container 90 can be transferred from the merge station conveyor 97 onto a conveyor 96 and onto a pickup station 94. The combined shipping and storage container 90 can be removed from the pickup station 94 by the movable load handler 40 and transported to the order picking station 4. FIG. 11 shows an exemplary view prior to lifting the empty storage container 70 on the merge station conveyor. FIGS. 12 and 13 show the progression of an exemplary merging process, as the empty storage container is lifted to enclose the shipping container. FIG. 14 shows an exemplary view after the storage container 70 has been lifted and the shipping container 80 has been released to form a combined shipping and storage container unit. FIG. 15 provides a detailed view of the exemplary merge station 97 and transfer mechanism 93.

[0072]

[0077] While the above exemplary merging process describes how an empty storage container is lifted to receive a shipping container, in another embodiment, the shipping container may be positioned over the storage container by the transfer mechanism 93 or some other mechanism and lowered into the storage container.

[0073]

[0078] In other embodiments, some other additional or alternative mechanism may be used to place the shipping container in the storage container.

[0074]

[0079] In some instances, the sequence of operations for the merge process may be performed in reverse to remove the shipping container from the storage container.

[0075]

[0080] In some embodiments, one or more processors, controllers, and / or other control system devices (which may be generally referred to collectively as processors throughout this disclosure) can be configured to coordinate or otherwise control the timing of the operation of conveyors, clamps, lifting mechanisms, load handlers, etc. In some examples, this coordination can include timing the operation of clamps, lifters, and / or conveyors to ensure that shipping containers can be placed in or removed from storage containers quickly and efficiently.

[0076]

[0081] FIGS. 16-20 show an exemplary configuration 300 for extracting a completed shipping container 80 from a combined shipping and storage container 90. In FIG. 16, the process begins with a mobile load handler 40 placing the combined shipping and storage container 90 on a transfer platform 301. The shipping container 80 is then secured by a clamp 302, which can move vertically on a lift mechanism (not shown). In FIG. 17, while the shipping container 80 is secured by the clamp 302, in FIG. 18, the transfer platform 301 lowers and moves laterally, carrying the storage container 70 away from the shipping container. In FIG. 19, the clamp 302 can be moved down using a lift mechanism (not shown), placing the shipping container 80 at a transfer position 310 where a conveyor or other mechanism can transport the shipping container 80 to another location. In parallel, the transfer platform 301 can move up toward the transfer position with the clamp 304. 20, a conveyor 311 or other mechanism can carry a shipping container 80, for example, for loading onto a vehicle, while a storage container 70 can be secured by a clamp 304, returning the transfer platform 301 to a starting position to receive another combined shipping and storage container 90. A movable load handler 40 can remove the empty storage container 40 and place it, for example, in a machine such as those described in FIGS. 9-15 or in some other location.

[0077]

[0082] In some instances, the sequence of operations for the withdrawal process can be performed in reverse to place the shipping container into the storage container.

[0078]

[0083] The above examples may be used in addition to or instead of the mechanism described and illustrated with respect to Figure 8. In one embodiment, one or more suction devices may be used to hold the shipping and / or storage container and enable removal of the shipping container from the storage container.

[0079]

[0084] Such automation can be achieved by providing automatic controllers for the various systems and components described, including, for example, any or all of systems 1000, 400, 4, 3, 5, 6, 40, etc. Such automation can be provided in any suitable manner, including, for example, using an automatic data processor executing appropriately configured, coded, machine-readable instructions, using a wide variety of devices, some now known and some no doubt later developed. Processors suitable for use in such implementations include any one or more data processors, controllers, computers, and / or other systems or devices, as well as other devices or components, including the necessary or desirable input / output, communication, control, operating systems, and software suitable for achieving the purposes described herein. For example, a suitably programmed general-purpose data processor provided on one or more circuit boards would suffice.

[0080]

[0085] 21 shows an example method 2200 for handling a storage container. At 2210, one or more processors can be configured to generate a signal to place a shipping container into the storage container. In some examples, this can include generating a signal to control or direct at least one mechanism to raise the storage container to surround the shipping container or to lower the shipping container into the storage container.

[0081]

[0086] At 2220, the processor can be configured to generate a signal to store the combined shipping and storage container unit in the storage and retrieval system 400. In some examples, this can include generating a signal to control or command at least one mechanism (such as a conveyor and / or load handler) to transport the combined container unit and / or to store the combined container unit in a storage location within the storage and retrieval grid or other structure.

[0082]

[0087] In some embodiments, this same storage and retrieval grid or other structure can store storage containers containing inventory, for example, multiple interchangeable items can be stored within a single storage container within the storage and retrieval system.

[0083]

[0088] Upon receipt of a request to fulfill an order, or upon some other trigger, the processor can be configured to generate a signal to remove the shipping and storage container unit along with the storage container containing the item to be picked, at 2230. In some examples, this can include generating a signal to control or command at least one mechanism, such as one or more load handlers, to remove the requested container (containing the item or shipping container) and for picking or transport to workstation 4. In some examples, the processor can generate a signal to control or command at least one mechanism (such as a conveyor and / or shuttle) to pick or transport the container to workstation 4.

[0084]

[0089] The processor may be configured to coordinate the removal of containers based on any number of factors, including, but not limited to, load handler or other mechanism loading, transportation congestion, order priority, picking station priority, and the like. In some examples, removal of containers containing items and containers containing shipping containers may be performed simultaneously or in parallel by multiple load handlers or other mechanisms.

[0085]

[0090] In some examples, the removal of containers can be performed sequentially or time-independently of one another. For example, a container containing an item to be picked may already be at a picking station for a previous order, and then a container containing a shipping container can be removed and transported to the picking station to receive the item from the container used for the previous order. This order, or any other order or sequence, of removing the containers can be controlled by a processor in order to achieve high throughput, utilization, and / or efficiency.

[0086]

[0091] In some embodiments, when combined / nested, some or all empty shipping and storage container units can be transferred directly to a picking station or workstation instead of being stored in the storage and retrieval system (e.g., in 2220). This can optionally be done based on demand or based on system configuration or settings.

[0087]

[0092] At 2240, the processor can be configured to return a partially or fully picked shipping container stored in the storage container to the storage and retrieval system. This can be done similarly to 2220 or otherwise.

[0088]

[0093] In some examples, a partially picked shipping container (i.e., a container into which additional items will be picked) stored in a storage and delivery system can subsequently be retrieved and transported to a picking station or workstation for additional picking. In this manner, an order can be picked in one or more stages. In some examples, multi-stage picking may be utilized for lower priority orders or to partially fulfill potential orders. In some examples, multi-stage picking may occur when inventory is low or when leaving a container at a picking station may cause a resource backlog.

[0089]

[0094] In 2250, the processor can be configured to retrieve a shipping container stored in the storage container for shipping. In some examples, this can include controlling or generating a signal to command at least one mechanism (such as a conveyor and / or load handler) to retrieve the combined container unit from the storage and retrieval grid and / or transport it to a location for shipping. In some examples, this can also include controlling or generating a signal to command at least one mechanism (e.g., see FIGS. 8-20 ) to remove the shipping container from the storage container, as described herein or otherwise.

[0090]

[0095] In some examples, by storing shipping containers in a storage and retrieval system, a processor can be configured to retrieve shipping containers in a particular sequence or grouping in preparation for shipment. In some embodiments, the sequence or grouping can be determined / defined to simplify shipping activities such as container sorting, vehicle loading, order prioritization, etc. For example, a processor can be configured to generate a signal to retrieve all shipping containers for shipment in a particular vehicle, for a particular route, to a particular shipping window, to a particular destination, etc. A processor can be configured to retrieve shipping containers in a particular order for loading onto a vehicle and / or in a sequence related to the sequence in which the containers may be delivered.

[0091]

[0096] While the disclosure has been provided and illustrated in connection with specific, presently preferred embodiments, many variations and modifications may be made without departing from the spirit and scope of the invention disclosed herein. Accordingly, the disclosure and invention are not limited to the precise components or details of the methodology or structure set forth above. No particular order to steps or stages of the methods or processes described in this disclosure, including the drawings, is intended or implied, except to the extent necessary or inherent in the processes themselves. In many cases, the order of process steps may be varied without altering the purpose, effect, or intent of the methods described. The scope of the invention is defined solely by the appended claims, giving due consideration to the theory of equivalents and related theories. The inventions described in the claims of the present application as originally filed are set forth below. [C1] In a system for managing shipping containers, The system comprises: a storage and retrieval system and at least one processor; The storage and retrieval system comprises: a structural framework defining a grid of storage locations configured to receive a plurality of containers; a plurality of robotic load handlers for retrieving containers from any one of said storage locations; at least one rail disposed about the grid to allow access to each of the storage locations by at least one of the plurality of robotic load handlers; The at least one processor: generating a signal to command or control at least one of the plurality of robotic load handlers to store a storage container containing stored items in the storage and retrieval system; generating a signal to command or a signal to control at least one of the plurality of robotic load handlers to retrieve at least one container containing stored items from the storage and retrieval system and deliver the retrieved at least one container to an order picking station; A system configured to generate a signal to instruct or control at least one of the plurality of robotic load handlers to store at least one shipping container containing at least one picked item in the storage and retrieval system. [C2] The system of C1, wherein each of the at least one shipping container is stored in a storage container for storage in at least one of the storage locations. [C3] 3. The system of claim 1 or 2, wherein the at least one processor is configured to generate a signal to instruct or control at least one of the plurality of robotic load handlers to store a fully or partially picked shipping container in the storage and retrieval system. [C4] 4. The system of any one of claims 1 to 3, wherein the at least one processor is configured to generate a signal to instruct or control at least one of the plurality of robotic load handlers to store empty shipping containers in the storage and retrieval system. [C5] 5. The system of any one of claims 1 to 4, wherein the at least one processor is configured to generate a signal to instruct or a signal to control at least one of the plurality of robotic load handlers to retrieve at least one of the shipping containers and deliver the retrieved at least one shipping container to an order picking station. [C6] 6. The system of any one of claims C1 to C5, wherein the at least one processor is configured to generate a signal to instruct or a signal to control at least one of the plurality of robotic load handlers to retrieve at least one of the shipping containers for dispatch. [C7] The system of any one of claims C1 to C6, wherein the grid of storage locations is configured to receive multiple containers in one or more stacks. [C8] The system of any one of claims C1 to C7, comprising at least one mechanism for removing a shipping container from a storage container. [C9] The system described in C8, wherein the at least one mechanism includes at least one lifter mechanism configured to extend through one or more openings in the bottom of the storage container, engage the shipping container, and apply an upward force to the bottom of the shipping container. [C10] The system of C8 or C9, wherein the at least one mechanism includes at least one lifter mechanism configured to engage the shipping container using at least one of a lip, a handle, and an opening of the shipping container to lift the shipping container from the stackable container. [C11] The system of any one of C8 to C10, wherein the at least one mechanism includes a suction device. [C12] 1. A method of operating an order processing system having a cargo storage and retrieval system, comprising: The method comprises: storing a plurality of storage containers containing stored items in at least one of a plurality of storage locations in the storage and retrieval system using at least one robotic load handler; storing a plurality of shipping containers in at least one of a plurality of adjacent stacks using the at least one robotic load handler; using the at least one robotic load handler to retrieve a plurality of containers, including at least one of the shipping containers, from at least one of a plurality of storage locations and deliver the retrieved containers to an order picking station. [C13] The method of C12, comprising storing each of the plurality of shipping containers in a storage container for storage at at least one of the plurality of storage locations. [C14] The method of claim C12 or C13, further comprising using the at least one robotic load handler to store at least one shipping container containing at least one picked item in at least one of the plurality of adjacent stacks. [C15] 15. The method of any one of claims C12 or 14, comprising using the at least one robotic load handler to store at least one partially or completely picked shipping container in at least one of the plurality of adjacent stacks. [C16] The method of C15, comprising using the at least one robotic load handler to retrieve at least one of the shipping containers from at least one of a plurality of storage locations for shipment. [C17] The method of C16, comprising removing the at least one shipping container accepted for shipment from the at least one storage container with at least one lifter mechanism. [C18] The method of C17, wherein the at least one storage container from which the shipping container is removed includes one or more openings or cutouts, and removing the shipping containers includes using the openings or cutouts to allow at least the beginning of removal of each of the at least one shipping container. [C19] The method of any one of C12 to C18, comprising removing a shipping container containing items from a storage container and then placing an empty shipping container in the storage container. [C20] The method of any one of C12 to C19, wherein at least one of the plurality of shipping containers is nestable with at least one other shipping container.

Claims

1. 1. A cargo storage and retrieval system comprising: a framework defining a grid of storage locations, said grid storing a plurality of storage containers in rows and columns of stacks of storage containers, said plurality of storage containers configured to store inventory items in said plurality of storage containers; a plurality of overhead robotic load handlers for transporting the plurality of storage containers to and from the storage locations within the grid, the plurality of overhead robotic load handlers configured to travel on rails along the rows and columns of the grid; a plurality of shipping containers, each shipping container configured to deliver one or more ordered inventory items to a destination that are picked from one or more of said storage containers and placed in said shipping container, each shipping container configured to store as a combined container in said grid; wherein the combined container is formed from one or more shipping containers of the plurality of shipping containers stored within a storage container of the plurality of storage containers, the one or more shipping containers being removable from the storage container for delivery of the one or more shipping containers to the delivery destination with the one or more ordered inventory items contained within the one or more shipping containers. A system comprising:

2. An order picking station at which one or more ordered inventory items are picked from one or more of said storage containers and placed into a shipping container of said plurality of shipping containers; 2. The system of claim 1, wherein the system is configured to store one or more combined containers at one or more of the storage locations in the grid using one or more of the overhead robotic load handlers, the one or more combined containers each comprising one or more of the shipping containers containing one or more ordered items picked from one or more of the storage containers at the picking station.

3. 3. The system of claim 1, wherein each shipping container of the plurality of shipping containers is configured to be placed inside one of the plurality of storage containers such that a top edge of the shipping container does not protrude above a top edge of the storage container.

4. 4. The system of claim 1, wherein the plurality of shipping containers are nestable.

5. The system of claim 1 , wherein the plurality of storage containers are non-nestable.

6. 6. The system of claim 1, wherein each storage container of the plurality of storage containers is strong enough to support stacking of multiple storage containers of the plurality of storage containers within the grid.

7. 7. The system of claim 1, wherein each storage container of the plurality of storage containers is heavier than each shipping container of the plurality of shipping containers.

8. 8. The system of claim 1, wherein each shipping container of the plurality of shipping containers is contained within a corresponding storage container of the plurality of storage containers when the shipping container is stored in one of the storage locations in the grid.

9. 9. The system of claim 1, wherein the rails are on top of the grid of storage locations and are formed by the framework.

10. 1. A method of operating an order processing system having a cargo storage and retrieval system, the cargo storage and retrieval system comprising: a framework defining a grid of storage locations, said grid storing a plurality of storage containers in rows and columns of stacks of storage containers, said plurality of storage containers configured to store inventory items in said plurality of storage containers; a plurality of overhead robotic load handlers for transporting the plurality of storage containers to and from the storage locations within the grid, the plurality of overhead robotic load handlers configured to travel on rails along the rows and columns of the grid; a plurality of shipping containers, each shipping container configured to deliver one or more ordered inventory items to a destination, the inventory items being picked from one or more of said storage containers and placed in said shipping container; wherein the plurality of shipping containers and the plurality of storage containers are configured to form a plurality of combined containers, each combined container formed from one or more shipping containers of the plurality of shipping containers stored within a storage container of the plurality of storage containers, the one or more shipping containers being removable from the storage container for delivery of the one or more shipping containers to the delivery destination with the one or more ordered inventory items contained within the one or more shipping containers. Equipped with The method comprises: storing a first combined container of the plurality of combined containers in one of the storage locations within the grid using one or more of the plurality of overhead robotic load handlers, the first combined container being formed from one or more first shipping containers of the plurality of shipping containers stored in a first storage container of the plurality of storage containers.

11. The method includes the steps of picking one or more ordered items from a second storage container of the plurality of storage containers and placing the one or more ordered inventory items into the one or more first shipping containers; 11. The method of claim 10, wherein the storing step comprises the one or more first shipping containers containing the one or more ordered inventory items being picked from the second storage container.

12. retrieving the first combined container from the storage location within the grid using one or more of the plurality of overhead robotic load handlers, wherein the one or more first shipping containers contain the one or more ordered inventory items for delivery; removing the one or more first shipping containers from the first storage container; providing the one or more first shipping containers to a shipping facility for shipment of the one or more first shipping containers to the delivery destination with the one or more ordered inventory items contained within the one or more first shipping containers; The method of claim 10 or 11, comprising:

13. 13. The method of any one of claims 10 to 12, wherein when each combined container is formed, a top edge of the one or more shipping containers does not protrude above a top edge of the storage container.

14. 14. The method of any one of claims 10 to 13, wherein storing the first combined container comprises storing the first combined container in a stack of the stacks in the cargo storage and retrieval system.

15. using one or more of the plurality of overhead robotic load handlers to retrieve the first combined container from the storage location within the grid and deliver the first combined container to an order picking station. The method of any one of claims 10 to 14, further comprising:

16. transporting the first combined container within the cargo storage and retrieval system for storage prior to delivery using one or more of the plurality of overhead robotic load handlers. The method of any one of claims 10 to 15, further comprising:

17. 17. The method of any one of claims 10 to 16, wherein each storage container of the plurality of storage containers is heavier than each shipping container of the plurality of shipping containers.

18. 18. The method of any one of claims 10-17, further comprising removing the one or more first shipping containers from the first storage container.

19. 20. The method of claim 18, wherein removing the one or more first shipping containers is performed via at least one lifter mechanism configured to engage the one or more first shipping containers using at least one of a lip, a handle, and an opening of the one or more first shipping containers to lift the one or more first shipping containers from the first storage container.

20. 1. Use of a combined container in a cargo storage and retrieval system, said cargo storage and retrieval system comprising: a framework defining a grid of storage locations, said grid storing a plurality of storage containers in rows and columns of stacks of storage containers, said plurality of storage containers configured to store inventory items in said plurality of storage containers; a plurality of overhead robotic load handlers for transporting the plurality of storage containers to and from the storage locations within the grid, the plurality of overhead robotic load handlers configured to travel on rails along the rows and columns of the grid; a plurality of shipping containers, each shipping container configured to deliver one or more ordered inventory items that are picked from one or more of said storage containers and placed in said shipping container; wherein the combined container is formed from a storage container of the plurality of storage containers that includes one or more shipping containers of the plurality of shipping containers; the one or more shipping containers are removable from the storage container for delivery of the one or more shipping containers to a destination with the one or more ordered inventory items contained within the one or more shipping containers; 10. Use of a combined container comprising:

21. 21. The use of a combined container according to claim 20, wherein an upper edge of the one or more shipping containers does not protrude above an upper edge of the storage container.

22. 22. The use of a combined container according to claim 20 or 21, wherein shopping bags or shipping boxes are stored within said one or more shipping containers.

23. 23. Use of a combined container according to any one of claims 20 to 22, wherein the walls of the storage container are of suitable thickness and stiffness to support stacking within the stack of storage containers.

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