SYSTEM AND METHOD FOR PICKING ITEMS

Abstract

To provide a system that allows for the storage and retrieval of vast numbers of different inventory items.SOLUTION: A system and a method for picking items are disclosed. The system includes a grid-based storage area and an order assembly area. The system further includes an array of presentation positions (116), and the presentation positions are adapted to present storage containers (10) delivered to the presentation positions to enable picking of items contained therein.SELECTED DRAWING: Figure 8d

Description

[Technical Field]

[0001] The present invention relates to systems and methods for picking items from a storage system. More particularly, but not exclusively, the present invention relates to systems and methods for picking items to fulfill customer orders in an online retail environment, said order picking system including item presentation systems and devices. [Background technology]

[0002] Some commercial and industrial operations require systems that allow for the storage and retrieval of a vast number of different inventory items.

[0003] One known form of fulfillment center uses a fulfillment system known as "zone picking" or "pick and pass," as shown in FIG. 1. In such a system, items and inventory needed to fulfill a customer order are located in storage bins or containers, which are arranged along an aisle. A conveyor system is located across the aisle from the storage bins or containers and carries customer delivery bins or containers. The conveyor system is arranged to pass a portion of the delivery bins or containers traveling on a backline conveyor through a picking station via a station conveyor, and items ordered by the customer are transferred by an operator from the storage bins or containers to the customer delivery bins or containers. When a customer delivery container is positioned at a picking station on the conveyor system, it is paused and an operator selects the required item from the storage bin or container and places it in the customer delivery bin or container.

[0004] It will be appreciated that in certain market segments, such as online grocery retail, this known form of operation may require many picking aisles, many picking stations, and many operators to fulfill customer orders, thus requiring a large initial outlay. Furthermore, scaling such systems is difficult because the infrastructure design and location are fixed from the start.

[0005] In a further known type of system for storing and retrieving items of multiple product lines, the items are again located in storage bins or containers. However, in another known system, the bins or containers are arranged in stacks on top of each other, with the stacks arranged in rows. The storage bins or containers are accessed from above and removed from the stacks by a load handling device.

[0006] EP3030504B1 (Ocado Innovation Limited), the contents of which are incorporated herein by reference, describes a system in which a stack of containers is arranged within a frame structure. This type of system is illustrated diagrammatically in Figures 5 and 6 of the accompanying drawings. Robotic load handling devices are controllably moved on a system of tracks, which form a grid located above the stack of containers. In the robotic picking system described in EP3030504B1, the grid comprises a series of grid spaces defined by the tracks, with each stack of containers positioned within the footprint of a single grid space. In use, the robotic load handler travels on the tracks above the stack and is controllably positioned above a predetermined stack of containers. When in position, a lift mechanism is lowered into a position where a gripper device, part of the lift mechanism, engages the container and lifts the receptacle or container from the stack into a cavity within the load handling device. In this particular system, the cross section of the robotic load handling device substantially corresponds to the area of ​​a single grid space. Additionally, the track and robotic load handling device are configured so that the two load handling devices occupy adjacent grid spaces and pass each other in either direction during operation.

[0007] Other forms of robotic load handling devices are described, for example, in Norwegian Patent No. NO 317366 B1 (Autostore AS), the contents of which are incorporated herein by reference, and which disclose a cantilever-type load handling device which occupies two grid spaces in operation. In the context of the present invention, which will be described in more detail below with reference to specific embodiments, it will be understood that load handling devices of any form or configuration can be used in place of the two examples described above.

[0008] Such a storage system eliminates the need for aisles between storage and picking areas and also allows for higher density storage of products or items in a fulfillment center for a given volume.

[0009] In the known grid-based robotic picking systems described above, a storage bin or container being lifted from a stack may contain inventory items needed to fulfill a customer order. Once lifted by a load handling device, the storage bin or container is delivered by the load handling device to an output port above or adjacent to the picking station, or to the picking station itself. At the picking station, the required inventory items may be manually or robotically removed from the storage bin or container and placed into a shipping container, which forms part of the customer order and is filled for shipment at the appropriate time.

[0010] It will be appreciated that such an order may include multiple shipping containers, with the number of shipping containers required being dictated by the number of items or products ordered. Accordingly, multiple receptacles or containers may need to be moved from storage positions in the stack to the picking station.

[0011] Advantageously, the modular nature of the grid-based picking system allows the overall picking and storage system to be built in stages and expanded as needed, thereby spreading capital investment and costs as needed.

[0012] However, it will be appreciated that the movement of storage bins or containers to picking stations and the subsequent picking, whether manual or robotic, of inventory items from said storage bins or containers into shipping bins or containers may sometimes be delayed. Such delays at picking stations may cause congestion of the load handling devices at the system output ports or picking stations, causing delays in the assembly and therefore dispatch of customer orders.

[0013] This is a drawback of such systems in that each inventory item must be delivered to the picking station in a storage receptacle or container as needed, and there is no ability to keep frequently needed items at the picking station.

[0014] Furthermore, the number of picking stations in a grid-based system is limited by the space available for the picking station footprint, which results in frequently needed items and products having to be transferred multiple times by the robotic load handler, thereby increasing the number of required load handler movements and further increasing congestion at the output port.

[0015] Furthermore, such grid-based systems require that all inventory items be placed in a storage bin or container in order to be available for picking, which limits the system to inventory items that can be placed in the container or bin and requires an additional unpacking step to be performed as part of the picking system or method.

[0016] It will be appreciated that both of the known types of storage and picking systems described above operate under the control of a computer utility that acts to control the movement and location of storage receptacles or containers and shipping containers, the movement and location of inventory, and the location and number of workers required at any given point in the system. Additionally, in a grid-based system, the computer utility may control the movement and location of load handling devices and control communications between the load handling devices and the order picking system.

[0017] In view of the known systems described above, it may be beneficial to combine a grid-based storage and picking system with a traditional "zone picking" or "pick and pass" conveyor-based picking system, particularly where labor is relatively inexpensive and there is a concentration of frequently ordered or "fast moving" items. Summary of the Invention

[0018] According to the present invention, there is provided a system for picking items from a storage facility, the system including a grid-based storage system, the storage system including a series of storage containers, the storage containers containing items to be stored, the storage containers positioned in a stack within a framework, a portion of the framework including an output queue, the output queue having a plurality of presentation positions, the storage containers movable from storage positions within the stack via the output queue to said presentation positions away from the stack, the presentation positions arranged to position the plurality of storage containers on at least one face of the storage system, and the presentation positions arranged so that items stored in the storage containers are accessible to an item picker.

[0019] There is further provided in accordance with the present invention a method of picking items from a storage system using such a picking system.

[0020] In this manner, the present invention overcomes the problems of the prior art and provides a system and method that increases the speed at which customer orders can be accumulated while reducing overall costs and improving the efficiency of customer fulfillment centers or other industrial scenarios where items are stored and access to said items is required periodically.

[0021] The present invention will now be described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0022] [Figure 1]FIG. 1 is a schematic perspective view of one known form of a "zone picking" or "pick and pass" picking system, showing a picking aisle, a storage area, and two order assembly areas, the storage area further comprising storage bins or containers positioned to present a picking surface to an operator, the storage bins or containers comprising items, products, or inventory awaiting assimilation into customer orders. [Figure 2] FIG. 2 is a schematic plan view of the system of FIG. 1 showing in more detail an example of the storage area, picking surface, and one order assembly area, where the picking aisle includes a portion of the backline conveyor and station conveyor. [Figure 3] FIG. 3 is a schematic cross-sectional view of the order assembly area of ​​FIG. 1 through a picking aisle in the region of a picking station. [Figure 4] FIG. 4 is a schematic perspective view of a typical configuration of a storage area of ​​the system of FIGS. 1 to 3. [Figure 5] FIG. 5 is a schematic perspective view of one form of grid-based robotic picking system comprising a grid positioned above a stack of storage containers and a series of tracks disposed on the grid, the tracks carrying load handling devices adapted to pick up containers or receptacles from the stack below the grid. [Figure 6] FIG. 6 is a schematic perspective view of one form of known robotic load handling device for use with the grid-based storage area of ​​the zone picking solution of FIG. [Figure 7a] FIG. 7a is a schematic perspective view of an order picking system according to one embodiment of the present invention, the system including a storage area including a grid-based storage solution, the grid-based solution including a robotic picking system, the system accommodating multiple stacks of storage receptacles or containers in the storage area, and the grid-based system including an array of storage receptacle presentation positions. [Figure 7b]Figure 7b is a schematic side view of the order picking system of Figure 7a according to one embodiment of the present invention, the system comprising a plurality of load handling devices of the type shown in Figure 6 mounted on the frame structure of Figure 5 together with at least one robotic load handling device, the framework and load handling device together comprising the main components of a robotic storage and picking system for storage and handling of stored items. [Figure 7c] FIG. 7c is a schematic side view of one form of the order picking system of FIG. 7a in accordance with the present invention, showing pre-picking positions and presentation positions in the storage area, the system further comprising a mechanism for transferring storage containers or receptacles from the pre-picking positions to the presentation positions, and the order assembly portion comprising a trolley picking system. [Figure 8a] FIG. 8a is a schematic perspective view of a portion of a storage system representation of an order picking system according to one aspect of the present invention, where containers from a grid-based storage system are delivered to storage areas by a robotic load handling device. [Figure 8b] FIG. 8b is a schematic side view of the presenting portion of FIG. 8a showing a further form of mechanism for moving the container storage receptacle from the delivery location to the presenting position. [Figure 8c] FIG. 8c is a schematic perspective view of the system of FIG. 8b showing in more detail the mechanism for moving the storage containers. [Figure 8d] FIG. 8d is a schematic side view of a further embodiment of a storage area of ​​an order picking system according to one embodiment of the present invention, the system including a receptacle lift device for transferring storage containers or receptacles to presentation positions. [Figure 8e] FIG. 8e is a schematic perspective view of a further form of a storage area of ​​an order picking system according to one form of the present invention, the storage area comprising a series of shuttle devices operable on a frame comprising a looped track for transporting storage containers or receptacles to presentation positions. [Figure 8f]FIG. 8f is a schematic cutaway perspective view of the order picking system of FIG. 8e, showing in more detail the shuttle device of FIG. 8e operable on a looped track. [Figure 8g] FIG. 8g is a schematic perspective view of a further form of a storage area of ​​an order picking system according to one form of the present invention, the storage area comprising a series of shuttle devices operable on a track system, the shuttles engageable with framework uprights of a grid-based storage system. [Figure 8h] Figure 8h is a schematic side view of a further configuration of the storage area of ​​the order picking system of Figure 8g, showing the shuttle device in place within the framework uprights. [Figure 9] FIG. 9 is a schematic perspective view of a further form of order picking system according to the present invention, the order picking system comprising a further storage area comprising a grid-based storage area adapted for use with larger storage containers or pallets. [Figure 10] FIG. 10 is a schematic perspective view of a further form of the invention, in which the order picking system comprises a storage area having presentation positions of different sizes, and the grid-based storage system comprises portions sized to accommodate storage bins or containers of predetermined but varying sizes. [Figure 11] FIG. 11 is a schematic perspective view of a further aspect of the present invention in which grid-based storage areas are associated with a multi-level zone picking system in a CFC environment. [Figure 12] FIG. 12 is a schematic perspective view of a further embodiment of the present invention showing a complete customer fulfillment center (CFC) comprising a grid-based storage system with a zone picking order picking system on one side, and the remaining grid-based system comprising picking stations and peripheral equipment adapted to function in said grid-based system. [Figure 13] FIG. 13 is a schematic diagram of a further embodiment of an order picking system in accordance with one embodiment of the present invention, the system comprising two adjacent embodiments of picking stations. Detailed Description

[0023] In the following description, "storage container 10" will be used to refer to a container, receptacle, or tote intended for storage of inventory items, and "shipping container DT" will be used to refer to a container, receptacle, or tote intended to be filled to fulfill an order placed by a customer in an online retail environment or otherwise. It will be understood that this terminology is used within this document for ease of reference and description. However, it should be noted that storage container 10 and shipping container DT may be of the same shape and configuration. Furthermore, shipping container DT may be stored within receptacle 10 within a storage system or any portion thereof. It is the function of the receptacle, receptacle, or tote that defines the category of container, rather than any variation in actual size, shape, or configuration.

[0024] In one form of order picking system described below with reference to Figures 1-4, many picking aisles 100 can be arranged in a large warehouse environment, often referred to as a customer fulfillment center (CFC), but for ease of discussion, a single picking aisle 100 is described below and illustrated in Figures 1-4. It will be understood that the number of picking aisles 100 is limited only by the size of the warehouse building or CFC, and that the picking aisles 100 can be arranged in many different styles and configurations across many floors. The one example of a picking aisle 100 described below, while of a typical form, is set forth merely as an example and should not be considered limiting.

[0025] 1, one form of a zone pick fulfillment system comprises a picking aisle 100 bounded on one side by a product or item storage area 102 and on the other side by an order assembly area 104. Both the order assembly area 104 and the storage area 102 extend substantially along the length of the picking aisle 100 on either side.

[0026] The order assembly area 104 comprises two parallel conveyors or conveyor portions 106, 108 that travel along the picking aisle 100: a first "backline" conveyor 106 and second "station" conveyor segments 108a and 108b. The backline conveyor 106 is linked to the station conveyor portions 108a and 108b by a series of branches 110 and junctions 112.

[0027] The picking aisle 100 further comprises a series of picking stations 114 spaced apart along the length of the picking aisle 100, the picking stations 114 being positioned such that the station conveyor portions 108a and 108b pass through the picking stations 114a and 114b.

[0028] The storage area 102 of the picking aisle 100 comprises a series of presentation positions 116 for storage receptacles or containers 10 that, when receptacles or containers 10 or other forms of product, inventory, or items are stored in or on the appropriate storage receptacles, create a "picking surface" 118 that extends along the length of the picking aisle 100. The picking surface 118 includes multiple tiers of storage receptacles or receptacles 10 positioned to present items to be picked (not shown) to a worker 120 present in the picking aisle 100.

[0029] In use, a shipping container DT moves around the CFC, placing therein inventory items or products previously ordered by a customer as part of an order. In the case of a given shipping container DT, when the storage area 102 of a particular picking aisle 100 contains the items required for a given customer order and a given shipping container DT, it enters the above-mentioned picking aisle 100 when a control utility (not shown) routes said shipping container DT to that aisle 100. It will be understood that a shipping container DT may be routed through any picking aisle in the CFC or infrastructure, or there may be conveyor connections within the CFC that allow the shipping container DT to be routed only through the picking aisle 100 in which the item is to be picked.

[0030] As a delivery container DT passes along backline conveyor 106, if the storage area 102 in the area of ​​picking station 114a contains the product or item required in a given customer order associated with the given delivery container DT, the delivery container DT may be diverted to station conveyor 108a via divergence 110. If the storage area 102 in the area of ​​picking station 114a does not contain the required item or product for that given delivery container DT, the delivery container DT will bypass picking station 114a by proceeding along backline conveyor 106.

[0031] Upon arrival at picking station 114a, delivery container DT is brought to a controlled stop under the control of a computerized utility (not shown). While held at picking station 114a, worker 120 will pick the required inventory items or products into delivery container DT from identified storage containers or receptacles 10 located in storage area 102. Storage receptacles 10 may be identified by any suitable method. For example, a light may be activated at the appropriate presentation position 116. Alternatively, a display at picking station 114a may provide location information.

[0032] Once the required items have been picked into the shipping container DT, the shipping container DT is automatically moved onto the backline conveyor 106 via station conveyor section 108a and junction 112 under the control of a computer control utility (not shown). The shipping container DT then continues to move around the CFC and is routed by the computer control utility (not shown) to the required picking station 114 in any picking aisle 100 within the CFC.

[0033] It will be appreciated that the above is one form of zone picking system and that there are many possible variations and modifications to the above system. For example, delivery containers DT may be manually pushed onto and off the backline conveyor 106 or manually moved between picking stations 114.

[0034] In another example, a separate backline conveyor 106 is not provided, and so all delivery containers DT pass only along the station conveyor 108 and therefore pass through all picking stations 114. Furthermore, the delivery containers DT may automatically stop at the picking stations 114 or continue to move through them, with workers picking items therein while the delivery containers DT are moving. Furthermore, it will be appreciated that delivery containers DT can bypass complete picking aisles 100 and be routed only through aisles 100 that have items that need to be picked for the associated delivery container DT.

[0035] In one further example, the conveyor systems 106, 108 are replaced entirely by a manual system of trolleys pushed around the CFC environment by workers who, guided by a computing device that displays item locations under the control of a computerized utility, move along a picking surface 118 to the required storage location 116. The computing device may be handheld or mounted on the trolley.

[0036] 3 and 4, the storage area 102 includes a framework 122 onto which storage containers 10 are placed by a crane device 124. The framework includes presentation positions 116 into which storage containers or containers 10 are positioned to form a picking surface 118 along the length of the picking aisle 100. The framework 122 further includes a storage location 126 (sometimes referred to as a pre-picking position) immediately behind the presentation position 116 in which the storage containers 10 are positioned. The storage location 126 typically includes a storage container 10 having the same inventory items therein as the storage container 10 in the presentation position 116 during the picking surface 118. However, this need not be the case.

[0037] The remaining storage positions 128 contain storage containers 10 having other inventory items therein. It will be understood that the inventory items may be of the same type as those in the storage containers 10 at presentation positions 116 and storage locations 126, in the case of fast moving goods, or other slower moving inventory items that may only require less frequent replacement of the storage containers 10 at presentation positions 116.

[0038] In use, once the storage container 10 at any given presentation position 116 is emptied, for example, when the worker 120 picks the last inventory item from the storage container 10 at the presentation position 116, the worker 120 removes the empty storage container 10 to an alternate remote location, and the storage container 10 positioned in the immediately following pre-picked storage position 126 is moved to the presentation position 116. The crane device 124 then fills the empty pre-picked storage position 126 with additional storage containers 10 having needed inventory items therein.

[0039] It will be appreciated that the storage container 10 at the pre-picking position 126 may be moved to the presentation position 116 manually, for example, by the worker 120 pulling the storage container 10, or automatically by a conveyor that is powered or operates under gravity. It will be appreciated that there are many ways to move the storage container 10 from the pre-picking position 126 to the presentation position 116. It will also be appreciated that the storage container or container 10 at the pre-picking storage position 126 may contain the same type of inventory item as is positioned in the storage container 10 at the presentation position 116. However, the computerized utility may determine that a storage container 10 containing a substitute inventory item could be more appropriately positioned at the presentation position 116 for a future order and may provide for this in advance by pre-positioning the appropriate storage container 10 at the storage position 126.

[0040] In this way, the items presented to the worker 120 may change dynamically over time and may be governed by knowledge of future orders or other external influences such as seasonal changes.

[0041] A drawback of the above-described zone picking system is that the storage area can become a single point of failure. If a crane device 124 in any given picking aisle 100 fails, it will affect the use of that picking aisle 100. This may, for example, limit the use of the picking aisle 100 to only those items remaining in storage containers 10 already at the picking surface 118. Prolonged inactivity of a crane device 124 can cause problems for the entire CFC environment, and in extreme cases, customer orders may be incomplete.

[0042] A further problem with the storage areas of the picking aisles 100 described above is the need to control the speed of rotation of items and products stored at locations within the storage area 102 to ensure that any one crane device 124 in any one picking aisle 100 is not overloaded.

[0043] In the following description, features common to the exemplary systems and embodiments of the present invention described above will be identified using the same reference numerals.

[0044] 5, 6, and 7, one embodiment of the present invention is described in which stackable storage containers 10 are stacked on top of each other to form a stack 12. The stack 12 is placed in a frame structure 14 in a warehouse or manufacturing environment.

[0045] 5 is a schematic perspective view of the framework 14. Each bin 10 typically holds multiple products or inventory items 28, and the inventory items within a bin 10 may be the same or may be of different product types depending on the application served by the picking aisle 100. Additionally, a bin 10 may be physically subdivided to accommodate multiple different inventory items 28.

[0046] The frame structure 14 includes a plurality of upright members 16 supporting horizontal members 18, 20. A first set of parallel horizontal members 18 are arranged perpendicular to a second set of parallel horizontal members 20 to form a plurality of horizontal lattice structures supported by the upright members 16. The members 16, 18, 20 are typically fabricated from metal. The storage containers 10 are stacked between the members 16, 18, 20 of the frame structure 14, so that the frame structure 14 guards against horizontal movement of the stack 12 of storage containers 10 and guides vertical movement of the storage containers 10.

[0047] The top level of the frame structure 14 includes rails 22 arranged in a grid pattern 22 across the top of the stacks 12. Referring further to FIG. 6 , the rails 22 support a plurality of robotic load handling devices 30. A first set 22a of parallel rails 22 guides movement of the load handling devices 30 in a first direction (X) across the top of the frame structure 14, and a second set 22b of parallel rails 22 is disposed perpendicular to the first set 22a and guides movement of the load handling devices 30 in a second direction (Y) perpendicular to the first direction. In this manner, the rails 22 enable movement of the load handling devices 30 in two dimensions, in the XY plane, so that the load handling devices 30 can be moved to a position above any of the stacks 12.

[0048] Each load handling device 30 includes a vehicle 32 positioned to move in the X and Y directions on the rails 22 of the frame structure 14 above the stack 12. A first set of wheels 34, consisting of a pair of wheels 34 at the front of the vehicle 32 and a pair of wheels 34 at the rear of the vehicle 32, are positioned to engage two adjacent rails of the first set 22a of rails 22. Similarly, a second set of wheels 36, consisting of a pair of wheels 36 on each side of the vehicle 32, are positioned to engage two adjacent rails of the second set 22b of rails 22. Each set of wheels 34, 36 can be raised and lowered so that either the first set of wheels 34 or the second set of wheels 36 is engaged with the respective set of rails 22a, 22b at any one time.

[0049] When the first set of wheels 34 is engaged with the first set of rails 22a and the second set of wheels 36 is fully lifted off the rails 22a, the wheels 34 can be driven to move the load handling device 30 in the X direction via a drive mechanism (not shown) housed in the vehicle 32. To move the load handling device 30 in the Y direction, the first set of wheels 34 is fully lifted off the rails 22a and the second set of wheels 36 is lowered into engagement with the second set of rails 22a. The drive mechanism can then be used to drive the second set of wheels 36 to achieve movement in the Y direction.

[0050] In this manner, one or more robotic loading and handling devices 30 can move around the top surface of the stack 12 on a frame structure 14 as shown in Figure 4 under the control of a centralized control utility (not shown). Each robotic loading and handling device 30 is provided with lifting means 38 for lifting one or more containers 10 from the stack 12 to access the required products.

[0051] The body of the vehicle 32 includes a cavity 40 sized to hold the container 10. The lifting means 38 preferably includes a winch means and a storage container gripper assembly 39. The lifting means 38 lifts the storage container 10 from the stack 12 into the cavity 40 in the body of the vehicle 32.

[0052] In this manner, multiple robotic load handling devices 30 can be used on a grid-based storage system to access multiple products from multiple locations in the grids and stacks 12 at any one time.

[0053] A first embodiment of an order picking system according to one aspect of the present invention is shown in Figures 7a, 7b, and 7c. As can be seen in Figure 7a, the first embodiment includes a picking aisle 100 and a storage area 102 including presentation positions 116 at which storage containers 10 are positioned to create a picking surface 118.

[0054] 7a, 7b, and 7c, in the context of an order picking system according to one aspect of the present invention, a robotic load handling device 30 removes a storage container 10 from a stack 12 containing an inventory item 28 required for picking a customer order therein. The load handling device 30 then transports the required storage container 10 to an output port 130, as shown in more detail in FIG. 7b. At the output port 130, the storage container 10 is lowered by the load handling device 30 onto a landing 132 at a pre-picking position 126.

[0055] As shown in FIG. 7 b, the pre-picking position 126 to which the storage container 10 is lowered depends on the presentation position 116 at which the storage container 10 is ultimately located. Typically, there are three presentation positions 116 positioned substantially in a row arrangement along the picking surface 118, although it will be understood that this depends on the size of the storage container 10, with larger storage containers 10 resulting in fewer presentation positions 116 on the picking surface 118 and smaller storage containers 10 resulting in a greater number of presentation positions 116 on the picking surface 118. Furthermore, the arrangement of the presentation positions 116 may depend on the drop-off location and the arrangement of the landing portion 132. Any suitable arrangement of presentation positions 116 in the picking aisle 100 appropriate to achieve the required throughput of storage containers 10 in the particular context of the picking system can be envisioned.

[0056] As shown in more detail in FIG. 7b, an alternating set of pre-picking positions 126 may be required to ensure that the pre-picking positions 126 for a presentation position 116 do not affect storage containers 10 lowered to other pre-picking positions 126 by alternate load handling devices 30. Advantageously, this can ensure that "faster moving" inventory items 28, i.e., those more frequently ordered by customers or those of which customers typically order multiples, are continually and regularly placed in pre-picking positions 126 to allow for quick replacement of a storage container 10 in a presentation position 116 when it is empty. As previously mentioned, the same item or product need not be in each of the storage containers 10 in the pre-picking positions 126.

[0057] As shown in more detail in the simplified side view of FIG. 8 a, each pre-picking position 126 comprises a landing 132 onto which the load handling device 30 deposits the storage container 10. The landing 132 comprises a device that acts as a means for moving the storage container 10 substantially laterally, in a controlled manner, from the drop position towards the presentation position 116 when required by the operator 120 in the picking aisle 100. There are many ways in which one skilled in the art can achieve this objective, and the following examples should not be considered limiting, as it will be understood that any suitable form of mechanism may be used to fulfill this function.

[0058] One form of the movement device may include a drive roller conveyor section 133 positioned on the landing portion 132, as shown in Figure 7b. The drive conveyor 133 may comprise a series of rollers that are powered such that upon activation of a driver, any storage container 10 in an appropriate position on the landing portion 132 will move under the control of the drive conveyor section 133 to the next pre-picked storage position 126 or to the presentation position 116.

[0059] It will be appreciated that the conveyor section 133 may be driven by a motor or any other suitable form of driver, but may also be manually activated by a lever, crank, or other mechanical device under the control of the operator 120.

[0060] The conveyor section 133 may further include a container stop (not shown) that acts to prevent a storage container 10 from moving from the landing portion 132 to the pre-picking position 126 or the presentation position 116. The container stop may be under the control of a computerized utility, thereby allowing the system to control the movement of a storage container 10 to the presentation position 116 only when a previously depleted storage container 10 at the presentation position 116 has been removed by an operator.

[0061] Each output port 130 comprises a grid space defined by tracks or rails 22 in the grid-based storage area 102. Below the output port 130 is a row of the storage area 102 that does not contain stacks 12 of storage containers 10, which row serves as row 131, below which the load handling device 30 deposits one or each storage container 10 that needs to be delivered to the picking surface 118. The output row 131 further comprises sensor means (not shown) for detecting the presence or absence of the lift device 38 and / or storage container gripper assembly 39 at the output row 131. The output row further comprises sensor means (not shown) near the landing 132 for detecting the presence or absence of a storage container 10 on the landing 132.

[0062] 7a, 7b, and 7c operate as follows: The robotic loading and handling device 30 is controllably moved to a position above a stack 12 of storage containers 10, with the top storage container 10 containing an item that needs to be picked for a customer order in an online retail environment. The robotic loading and handling device 30 lowers the lifting device 38, and the gripper assembly 39 of the storage container 10 engages the storage container 10 in the top position of the stack 12. The lifting mechanism 38 is retracted, and the storage container 10 is moved upwardly from the stack 12 and lifted into a cavity in the body 32 of the robotic loading and handling device 30.

[0063] Once the storage container 10 is fully within the body 32, the robotic loading handling device 30 moves to the output port 130 under the control of the computer-controlled utility. At the output port 130, once positioned above the output queue 131, the robotic loading handling device 30 lowers the storage container 10, essentially reversing the lifting process of the storage container 10, and the lift device 38 lowers the storage container 10 until it is positioned on the landing 132. A sensor (not shown) in the output queue 131 near the landing 132 detects the presence of the storage container 10 on the landing 132, and the container gripper 39 is released from the storage container 10. Once released, the container gripper 39 is attracted to the body 32 of the loading handling device 30. The movement of the container gripper 39 is monitored by an additional sensor (not shown) in the output queue 131 to ensure that the loading handling device 30 is fully released from the storage container 10. When a storage container 10 is detected on the landing portion 132 and the container gripper 39 is detected as being released from the storage container 10, the computer controlled utility can act to drive the drive conveyor section 133 to move the storage container 10 to the presentation position 116 or a further pre-picking storage position 126, depending on the output row 131 in which the storage container 10 is located.

[0064] It will be appreciated that the drive roller conveyor section 133 is under the control of a computer controlled utility (not shown), and that the conveyor section 133 is only powered when a storage container 10 is in the proper position on the landing portion 132. The container stops act to prevent movement of the storage container 10 before the next storage container 10 position 116, 126 is free to accept the storage container 10.

[0065] Once the required storage container 10 is in the required presentation position 116 on the picking surface 118, a worker 120 can pick the item from there into a delivery container DT present on station conveyor 108a at picking station 114a in picking aisle 100. The delivery container DT containing the picked item can then travel along station conveyor 108a and merge with backline conveyor 106 via merge 112. The delivery container DT then travels via a conveyor connection (not shown) to another picking aisle 100 and proceeds to another picking station 114 within the CFC.

[0066] Once the required items to fulfill a customer order or portion of a customer order have been picked there, the delivery container DT is routed, under the control of a computerized utility, to a shipping area (not shown) for loading and dispatch to the customer.

[0067] It will be understood that presentation position 116 always contains a storage container 10 unless it is replenished with a storage container 10 from "pre-pick" position 126. However, in order to replace a storage container 10 containing an inventory item or product with a storage container 10 emptied by operator 120, the empty storage container 10 must be manually removed by operator 120. The empty storage container 10 may be manually collected by a further operator 120 and moved to an input port (not shown) of the storage area where further inventory items or products can be placed therein manually or robotically.

[0068] Alternatively, once the inventory item or product is depleted, the storage container 10 removed from the presentation location 116 is placed on the station conveyor 108 and / or backline conveyor 106 for removal to a remote location where the storage container 10 is returned to the storage area 102 for replenishment or other use. In a further aspect of the invention, an additional conveyor may be positioned above the station 108 and / or backline conveyor 106 or above the picking surface 118, for example, to remove the empty storage container 10 to the remote collection point (not shown).

[0069] However, it is an advantage of such a grid-based order picking and storage system that the storage containers 10 remain captured within the system. Manual movement of the storage containers 10 may need to be avoided as damage may be caused or cleaning may be required.

[0070] Thus, in another aspect of the first embodiment of the present invention, a picking surface 118 is provided with an input location to the storage area 102. The input location includes an empty presentation location 116 in the picking surface 118, where an operator 120 can place an empty storage container 10 on a moving device that acts to move the empty storage container 10 from the presentation position 116 to an empty pre-picking position 126 and back to the landing 132. Once the empty storage container 10 is in the appropriate position on the landing 132, a robotic load handling device 30 can be moved under the control of a computer-controlled utility to pick up the empty storage container 10 and pull the container 10 toward the body of the load handling device 30. The load handling device 30 can then be moved to a position where the empty storage container 10 is needed, or it can be refilled with an inventory item or product.

[0071] It will be appreciated that this is the reverse process of routing storage containers 10 containing inventory items or products to presentation positions 116. However, given the number of inventory items or products in each storage container 10 at presentation positions 116 in the picking plane 118, there will be a slower rotation of empty storage containers 10. Therefore, fewer reverse input presentation positions will be required along the length of the picking aisle 100. There may be as few as one input presentation position for every 30 output presentation positions 116.

[0072] In a further configuration of the first embodiment of the invention, a shipping container DT positioned at picking station 114 may be placed in a storage area once the required items have been picked therein. In the same way that an empty storage container 10 can be returned to a storage area via reverse presentment position 116, a shipping container DT can be placed in a storage container 10 and placed in a storage area for later assembly of the customer's complete order. In this manner, a customer order may be partially picked and stored in a storage area within a shipping container DT within a storage container 10 in stack 12.

[0073] It will be apparent to those skilled in the art that the moving conveyor section 133 need not comprise a driven roller conveyor section 133, but may comprise a driven belt conveyor. It will be appreciated that any other suitable form of driven conveyor capable of moving storage containers 10 under the control of a computer controlled utility in the order picking and storage system may be used.

[0074] In a further form of the first embodiment of the present invention, as shown in Figure 7c, the picking aisle 100, instead of the arrangement of conveyors 106, 108 and picking stations 114, includes a worker 120 moving a trolley 134 along the picking aisle 100. The trolley 134 carries a plurality of delivery containers DT that can be moved by the worker along the picking aisle 100 in front of the picking surface 118. In this form of the embodiment of the present invention, the worker 120 is provided with a computer controlled display and scanning device that contains item location information and predetermined delivery container DT position information associated with a given customer order.

[0075] The computer and / or scanner may be of any suitable form or configuration suitable for the purpose, and it will be understood that there are many forms of such devices that would be known to one skilled in the art for implementation in such a system as described herein. The computing device may be a stationary trolley and may use voice synthesis and voice recognition technology, but need not be so configured, and any suitable configuration for the purpose may be envisioned.

[0076] In use, workers 120 position trolleys 134 adjacent to presentation positions 116 where items are required as instructed by the computer controller. Each worker 120 picks an item from a storage container 10 at the appropriate presentation position 116, scans the item, and places the item in a shipping container DT on the trolley 134. The worker may also be required to scan the shipping container DT when placing the scanned item into a predetermined shipping container DT to ensure the correct item is in the correct shipping container DT.

[0077] The worker 120 then travels along the picking aisle 100, repeating the process until all items needed from a given picking aisle 100 have been picked into the appropriate delivery container DT on the trolley 134. The worker 120 can then proceed to and travel through other picking aisles 100 within the CFC as needed. Once all items needed to fulfill the portion of the customer order that includes the delivery container DT on the trolley 134 have been picked, the trolley 134 is moved for unloading and dispatch for onward transport to the customer.

[0078] Alternatively, completed shipping containers DT may be placed in storage bins 10 and placed in grid-based storage areas 102 for future picking, combining with other related shipping containers DT for a given order, or dispatch. Nested storage bins 10 and shipping containers DT may be routed to remote locations for manual, automated, or robotic exchange in the system via any of the conveyor means described above.

[0079] It will be appreciated that in any given CFC operation, a combination of conveyor picking aisles 100 and trolley 134 picking aisles and workers 120 may be used to fulfill all or a portion of a customer order.

[0080] It will be appreciated that in the first embodiment of the present invention, by using a grid-based storage area 102, all presentation positions 116 in all picking aisles 100 can be serviced at all times. A failure of a load handling device 30 does not cause the system to cease operation, unlike a typical storage area 102 currently serviced by a crane device 124.

[0081] A second embodiment of the present invention will now be described with reference to Figures 8a, 8b and 8c. Items referred to in the systems described above in both the introduction and the first embodiment of the present invention retain the same reference numbers.

[0082] Figure 8a shows a schematic perspective view of an alternative configuration of storage area 102 located in picking aisle 100 of a CFC. Conveyors 106, 108, picking station 114 and order assembly area may be as described with reference to Figures 7a and 7b, or alternatively, a trolley picking solution as in Figure 7c may be envisaged.

[0083] The storage area 102 of the second embodiment remains of the grid-based type, comprising stacks 12 of storage containers 10 positioned within a framework 14, with uprights 16 supporting a grid structure positioned above the stacks 12. Load handling devices 30 operate on tracks 22 mounted on the grid structure of the framework 14. The grid structure defines grid spaces into which the footprints of the stacks 12 of storage containers 10 fit.

[0084] As in the first embodiment, the framework 14 further defines a number of output ports 130 and output rows 131, and storage containers 10 can be lowered down the output ports and output rows by the lift device 38 and container gripper device 39 of the load handling device 30.

[0085] In the second embodiment of the invention, the output train 131 again includes a series of landing portions 132. However, in the second embodiment of the invention, the landing portions 132 include a roller conveyor section 233. The roller conveyor section 233 of the second embodiment is not powered or driven. The roller conveyor 233 comprises a series of rollers 234 mounted to an undercarriage 236. The rollers are free to rotate when positioned in the undercarriage 234.

[0086] 8a and 8b, each output port 130 and output queue 131 associated with a given presentation position 116 includes a different number of roller substructures 236, with the alternating number of landing positions 132 again being defined by the number of presentation positions 116 required in the picking surface 118. The specific number of landing portions 132 and output ports 130 and queues 131 may differ from those shown and described in this example.

[0087] The understructures 236 of the landing sections 132 are positioned within the output row 131 in a similar manner as described above with reference to the first embodiment of the invention. When intact within the output row 131, each landing section 132 comprising its understructure 236 is positioned in a substantially horizontal position with reference to the uprights of the framework 14 of the storage area 102 when no storage receptacles 10 are positioned thereon. As shown in Figure 8b, the top landing section 132 without a storage receptacle 10 comprises its understructure 236 positioned within the output row 131 in a substantially horizontal manner with respect to the uprights of said row 131.

[0088] Note that the remaining landing portion 132 in Figure 8b includes a storage container 10 positioned on rollers of a base structure 236. However, the occupied base structure 236 with the storage container thereon is inclined relative to the horizontal. Although the drawing is not to scale, the angle may be 5 degrees from the horizontal, although it will be understood that any angle suitable for the required purpose may be used.

[0089] The understructure 236 further includes two guide uprights 238 mounted on said understructure 236 substantially perpendicular to the base of the understructure 236. The guide uprights 238 extend upward from two corners of the shorter sides of the understructure 236 substantially parallel to the framework uprights 14 of the framework 14 in the output row 131 of the storage area 102. The guide uprights 238 are positioned on the understructure 236 in the landing portion 132 so as to guide the storage containers 10 lowered thereon. The guide uprights 238 extend upward from the understructure and are sized to be taller than the height of the storage containers 10 when in use in the system.

[0090] The undercarriage 236 of the landing section 132 is pivotally mounted within the output row 131. In this manner, the landing section is free to tilt downwardly toward the presentation position 116 by a predetermined angle.

[0091] Each landing portion 132 is provided with a storage container 10 stop device 240. The container stop device 240 is rotatably mounted on each of the landing portion 132 and the presenting portion 116 below rollers mounted on the base structure 236. The container stop device may include a substantially vertically extending member 242 that can protrude between the rollers mounted on the base structure 236. The container stop device 240 may further include a longitudinally extending portion (not shown) below the rollers connected to the vertically extending member 242, the longitudinally extending portion being pivotally mounted to the base structure 236. In this embodiment, the container stop 240 is substantially L-shaped. One of the rollers (not shown) in the roller bed mounted on the base structure 236 is spring-loaded into the base structure 236 and acts to influence the longitudinally extending portion of the container stop device 240 below the roller when pressed down by the presence of a storage container 10 on the roller bed. The container stop device 240 can be moved from a first position in which the vertically extending member 242 protrudes through the rollers to a second position in which the vertically extending member 242 is below the top surface of the rollers. There may be a mechanical advantage such that small movements in the rollers are magnified into larger movements of the vertically extending portion 242. Movement of the spring-mounted rollers under the force of the storage container 10 on the rollers pivots the longitudinally extending member such that the vertically extending portion 242 protrudes through the rollers.

[0092] 8a, 8b and 8c, a storage container 10 is transferred to the output port 130 as described above with reference to the first embodiment of the invention. The storage container 10 is lowered down the output queue 131 by the lifting means 38 of the load handling device 30. As the storage container 10 approaches the landing position 132, the storage container 10 begins to engage the guiding uprights 238 of the undercarriage 236. The lifting means 238 continues to lower the storage container 10 until it is in the appropriate position on rollers rotatably mounted to the undercarriage 236. Once in this position, the gripper assembly 39 of the lifting device 38 is released from the storage container 10 and is drawn towards the load handling device 30.

[0093] As the gripper device 39 is released and moves upward, it clears the top of the guiding upright 238. Once the gripper device 39 clears this top of the guiding upright 238, the undercarriage 236 is free to pivot downward from the substantially horizontal position towards the presenting position 116.

[0094] As the rollers mounted within the undercarriage 236 rotate freely, the storage container 10 moves toward the presentation position 116 under the weight of the storage container 10 under the force of gravity.

[0095] In the case of the top landing position 232 and presentation position 116 of Figure 8b, when the storage container 10 remains on the lower structure 236 of the landing portion 132 and the gripper device 39 of the load handling device 30 retracts, the lower structure 236 tilts downward at the end adjacent to the presentation position 116 and the storage container 10 moves under gravity to the presentation position 116.

[0096] In this example, since there is no storage container at the top presentation position 116 of the picking surface 118, the container stop device 240 does not operate and the storage container rolls freely forward on the rollers from the landing position 132 of the pre-picking position 126 to the presentation position 116a.

[0097] Referring to the second tier of storage containers 10 in pre-picking positions 126 in FIG. 8 b, the presence of a storage container 10 in presentation position 116 acts to activate container stop device 240 .

[0098] Movement of the spring-loaded rollers under the force of the storage container 10 on the rollers of the presentation portion 116 pivots a longitudinally extending member beneath the roller, causing a vertically extending member 242 of the container stop device 240 to protrude through the roller at a position on the roller bed adjacent the first pre-picking position 126b, thereby preventing the storage container 10b' from rolling under gravity into the storage container 10 at the presentation position 116b. In a similar manner, the presence of the storage container 10b' in the pre-picking position 126b activates a container stop 240 in the substructure 236 of the roller conveyor section at the pre-picking position 126b. The activated container stop 240 prevents the storage container 10b'' from rolling under gravity from the landing portion 132b into the storage container 10b' at the pre-picking position 126b.

[0099] From the above and with reference to Figures 8b and 8c, it will be appreciated that the presence of a storage container 10 on any roller conveyor section 133 will activate the container stop device 240, preventing the next storage container 10 in the system from moving under gravity to its next position in the system.

[0100] It will be appreciated that the container stop device 240 must be used in this manner because manually removing a storage container 10 in a presentation position 116 may require excessive force if there are no pre-picked storage containers 10 stopped by the container stop device 240. Furthermore, removing a storage container 10 in a presentation position 116 may cause any unstopped storage containers 10 to move rapidly under gravity, potentially causing injury or damage to the worker 120 or the items and products within the storage containers 10.

[0101] It will be appreciated that the container stop device 240 described above with reference to Figures 8b and 8c is just one form of container stop mechanism that may be used, and that any other mechanical, electromechanical, magnetic, or any other suitable form of container stop device capable of stopping the movement of a container on a gravity-fed roller conveyor section may be used.

[0102] An advantage of the second embodiment of the present invention is that the system for moving the storage container 10 from the point where it was placed by the load handling device 30 to the presentation position 116 is a relatively simple and effective mechanical system that does not require power. This reduces the complexity of the system and eliminates the need for a computer control utility to control the precise movement of the storage container 10 towards the picking surface 118.

[0103] As with the first embodiment described above, it will be appreciated that empty storage containers 10 may be input to the system at specially configured presentation positions 116 that act in the same manner as described above with respect to the storage containers 10 being supplied to the presentation positions 116. However, mechanical systems are also contemplated. The input positions may also be powered in the manner described with reference to the first embodiment. Again, fewer input positions are required compared to the number of output presentation positions 116.

[0104] Again, it will be appreciated that the conveyor-based order assembly area 104 can be replaced with the trolley 134 picking solution described with reference to Figure 7c of the first embodiment, with the use of trolley picking aisles remaining as described above.

[0105] A third embodiment of the present invention will now be described with reference to Figure 8d. Items referenced in the preamble and in the systems described above in both the first and second embodiments of the present invention retain the same reference numbers.

[0106] A third embodiment of the present invention includes an alternative form of output column 331 and its method of operation.

[0107] The output queue 331 of the third embodiment includes a container lift device 300. The container lift device 300 is operable within the output queue 331 and serves all presentation positions 116 in the picking aisle 100.

[0108] The container lift device 300 includes a landing portion 332 that includes a section of the powered conveyor 304. The container lift device 300 moves up and down the output queue 331 under the control of a computer control utility (not shown). The container lift device 300 may comprise any suitable form of lift device capable of receiving a storage container 10 delivered by the load handling device 30 and transporting said storage container 10 to a presentation position 116 on a picking surface 118 of a storage area 102 of a picking aisle 100.

[0109] In use, the load handling device 30 lowers a storage container 10 into the output row 331 through the output port 30. The container lift device 300 may be moved upward in the row to accommodate the storage container 10 being lowered by the load handling device 30.

[0110] The storage container 10 is placed on the landing portion 332 of the lifting device 300 and the container gripper 39 of the lifting means 38 is released from the storage container 10 and retracted into the body 32 of the load handling device 30 .

[0111] Once the storage container 10 is still on the landing portion 332 of the container lift device 300, the container lift device 300 is moved adjacent to the present position 116 of the picking surface 118 of the picking aisle 100 in the CFC. The drive roller conveyor of the landing portion 332 of the container lift device 300 is activated to drive the storage container 10 from the container lift device 300 to the present position 116. Once the storage container 10 is still in the present position 116, the container lift device 300 can be moved to the top of the output queue 331 to accommodate another storage container 10.

[0112] In this way, a single container lift device 300 can operate at each output queue 331 of the picking face 118, avoiding a single point of failure but wasting less storage space than with pre-picking positions 126.

[0113] It will be appreciated that in this case of the third embodiment, a single output queue 331 can service the presentation positions 116 of two picking aisles, one on each side of the queue 331. It is also possible for a single output queue to service multiple levels of picking aisles 100. For example, in one form of the third embodiment of the present invention, two picking aisles 100 are located on the ground floor and two picking aisles 100 are located on the mezzanine level directly above.

[0114] It will be understood that a grid-based storage system may be located on the first floor, but extend upwardly across many floors. In this case, a single output queue 331 may service presentation positions 116 on both the first and mezzanine levels, with the system having a picking surface 118 on each floor. It will be understood that a receptacle lift device 300 is required at any output queue 331 having a presentation position 116 thereon.

[0115] In another form of the invention, with reference to Figures 8e and 8f, the container lift devices 300 present in each output row 331 as described above are replaced by a series of shuttle devices 310. Each shuttle device 310 is movable about a frame 340 which is inserted between the uprights of the output row 331, as shown in Figure 8f.

[0116] The frame 340 comprises two tracks, each having a first portion 342 that is substantially horizontal and extends longitudinally along the base of the output row 331, and a second portion 344 that is substantially horizontal and extends longitudinally along the underside of the rail or track along which the load handling device 30 is operable.

[0117] First and second track sections 342 and 344 are linked by a plurality of substantially vertically extending track sections 346, the number of substantially vertically extending track sections 346 corresponding to the number of uprights in output row 331. In this manner, the pitch of substantially vertical track sections 346 substantially matches the pitch of the uprights in output row 331. Frame 340 is positioned between the uprights in output row 331 to create a framework against which shuttle device 310 can travel.

[0118] Each shuttle device 310 comprises a vehicle base 312, which carries a section of conveyor 333. Each shuttle device 310 further comprises wheels or some other suitable form of movement mechanism, which are adapted to be further captured and moveable within or on tracks 342, 344, 346 of frame 340.

[0119] Track portions 342, 344 and track section 346 of frame 340 may comprise longitudinally extending slotted extrusions, and the wheels or movement means comprise gear or wheel mechanisms captured within the slotted extrusions.

[0120] However, it will be appreciated that there are many ways known to those skilled in the art to achieve this goal. For example, the track may not be grooved, but may be of C-shaped cross section, with the catch wheel mechanism held in place by the distal end of the C-shape.

[0121] The joints (not shown) between the substantially vertically extending track section 346 and the substantially horizontal longitudinally extending track sections 342, 344 are adapted to allow the wheels or movement means of the shuttle device 340 to move from the substantially vertically extending section of the track 346 to the substantially horizontally extending portions of the tracks 342, 344.

[0122] In this way, the shuttle device can pass along the base of the output row 331 of the storage area 102 on track portion 342, move up on track section 346 within output row 331, and move along the top track portion 344.

[0123] It will be appreciated that the nature of the frame 340 allows for multiple shuttle devices to be operable on the frame at any one time, as the shuttle devices 340 can pass along a substantially horizontal longitudinally extending track 342 below the shuttle devices 340 which are positioned on a substantially vertical section of the track 346 and are operable thereon.

[0124] In use, the load handling device 30 positioned at the top of the output row 331 lowers onto the shuttle device 310 the storage container 10 required for the presentation position 116 associated with the given output row 331. Once the storage container 10 is placed in place on the shuttle device 310, the gripper mechanism 39 and lift device 38 of the load handling device 30 are released from the storage container 10 and retracted or pulled into the load handling device 30.

[0125] Once the storage container 10 is released from the gripper device 39 and the gripper device 39 and lifting means 38 move away from the output row 331, the shuttle device 310 moves substantially vertically on a section of the track 346 within the output row 331 and pauses, under the control of the computer-controlled utility, at a level corresponding to the presentation position 116 where the storage container 10 needs to replace the previously removed storage container 10.

[0126] At the appropriate location, the conveyor 333 on the shuttle device 310 is activated to move the storage container 10 from the device to an empty presentation position 116 .

[0127] Once the storage container 10 is in the appropriate position at the presentation position 116, the shuttle device 310 may be repositioned to accommodate the next storage container 10. It will be appreciated that the next presentation position 116 that may require replenishment may be associated with the same output column 331 or may be associated with an alternative output column 331 that is positioned at a different position in the picking surface 118.

[0128] If the presentation position 116 is in the same output row, the shuttle device 310 and climbing means 316 act in the manner described above to receive the required storage container 10 and move it to the required position 116.

[0129] If the presentation position 116 to be filled by the delivered storage container 10 is in a different output queue 331, the shuttle device 310 moves either upward or downward on the track section 346, depending on the positions of the other shuttle devices and the location of the presentation position 116 to be filled. Upon reaching one of the substantially horizontally extending track sections 342, 344, the wheels or movement mechanism of the shuttle device 310 engage the associated portion of the track 342, 344 and, under the control of the computer-controlled utility, is moved to the base of the output queue 331 associated with the presentation position 116 to which the storage container 10 is to be delivered. At the appropriate position at the base of the required output queue 331, the shuttle device 310 engages the track section 346 and the shuttle device 310 is moved to the output queue 331. The procedure for receiving the storage container 10 and transferring the container 10 to the presentation position 116, as described above, is repeated.

[0130] It will be appreciated that the shuttle device 310 is controlled by a computer control utility common to all of the previously described embodiments and aspects of the invention.

[0131] In yet another form of the invention, in the context of this embodiment, as shown in Figures 8g and 8h, the receptacle lift device 300 of Figure 8d is again replaced by a shuttle device 310. The shuttle device 310 comprises a vehicle base 312, which carries a section of a drive conveyor 333. The shuttle device 310 is mounted on a substantially horizontal, longitudinally extending rail or track 313 that runs substantially parallel to the picking surface 118 at the base of the storage area 102, the longitudinally extending rail or track 313 passing beneath the base of the uprights 16 that delimit the output queue 331 of the grid-based storage area 102.

[0132] The shuttle device 310 further comprises wheels 314, or any other suitable form of movement means, adapted to enable movement of the shuttle device 310 in both directions along a longitudinally extending rail or track.

[0133] The shuttle device 310 further comprises climbing means 316 adapted to enable the shuttle device 310 to ascend up the output column 331. The climbing means 316 may take any suitable form that enables the shuttle device 310 to move up and down the output column 331 in a substantially vertical direction and that enables the shuttle device to pause at a position in the output column 331 that corresponds to the presentation position 116.

[0134] It will be appreciated that the climbing means 316 may be integrated with the shuttle device 310 or may take the form of a separately functioning lift device operated by the shuttle device 310, the separate lift device traveling up and down the output queue 331 and pausing at the presentation position 116.

[0135] In use, the shuttle device 310 is moved under the control of a computer controlled utility along a longitudinally extending rail or track to the base of the output row 331. Once in the appropriate position at the base of the desired output row 331, the climbing means engages the uprights of the output row 331 and moves upwardly under the control of the computer controlled utility.

[0136] 8e and 8f, the load handling device 30 positioned at the top of the output row 331 lowers onto the shuttle device 310 the storage container 10 required for the presentation position 116 associated with the given output row 331. The gripper mechanism 39 and lift device 38 of the load handling device 30 are then released and the storage container 30 is retracted or pulled into the load handling device 30. Once the storage container 30 is released from the gripper device 39, the shuttle device 310 moves vertically downward and pauses, under the control of a computer-controlled utility, at a level corresponding to the presentation position 116 where the storage container 10 needs to replace the previously removed storage container 10.

[0137] At the appropriate location, the conveyor on the shuttle device 310 is activated and the storage container 10 moves from the device to an empty presentation position 116. Once the storage container 10 is in the appropriate location at the presentation position 116, the shuttle device 310 can be positioned to receive the next storage container 10.

[0138] It will be appreciated that the next presentation position 116 requiring replenishment may be associated with the same output column 331 or may be associated with an alternative output column 331 positioned at a different position within the picking surface 118.

[0139] If the presentation position 116 to be filled by the delivered storage container 10 is in the same output row, the shuttle device 310 and climbing means 316 act in the manner described above to receive the required storage container 10 and move it to the required position 116.

[0140] If the presentation position 116 to be filled by the delivered storage container 10 is in a different output row 331, the shuttle device 310 is moved downwardly via the climbing means 316 towards the base of the output row 331. At the base of the output row 331, the shuttle device 310 engages a longitudinally extending rail or track 313 and, under the control of the computer controlled utility, is moved to the base of the output row 331 associated with the presentation position 116 to which the storage container 10 is required to be delivered. At the appropriate position at the base of the required output row 331, the shuttle device 310 engages the uprights of the output row 331 and the above procedure is repeated.

[0141] It will be appreciated that in the embodiments described with reference to any of Figures 8d, 8e, 8f, 8g and 8h, the conveyor 333 on the shuttle device 310 may be a driven roller conveyor or a driven belt conveyor and may be powered by any suitable means.

[0142] Using the shuttle device 310 in the manner described in any of the embodiments described with reference to Figures 8d, 8e, 8f, 8g and 8h allows multiple rows to be serviced by a single shuttle device 310.

[0143] It will be appreciated that, as shown in Figures 8e, 8f, 8g and 8h, multiple shuttle devices 310 may operate on longitudinally extending rails or tracks so that one shuttle device 310 can pass under a shuttle device 310 at an appropriate position within the output row 331.

[0144] It will further be appreciated that a longitudinally extending rail or track 318 at the top of the output queue 331 may run the length of the picking surface 118 substantially parallel to the rail or track 313 at the base of the storage area 302. Note that while only a single rail or track 313 is required at the base of the output queue 331, a pair of rails or tracks 318 is required at the top of the output queue so that the shuttle devices 310 and the rails or tracks 318 they follow do not affect the operation of the load handling devices 30 and the movement of the storage receptacles 10.

[0145] In this way, the shuttle device 310 is able to pass up and down the output rows 331, as well as up one output row 331 and down said output row 331, across the top of said output row 331, below the level of the surface on which the load handling device 30 is operable and along the underside of said surface to a further output row 331. To achieve this, it will be appreciated that the shuttle device 310 comprises at least one retention mechanism adapted to engage with a bottom longitudinally extending rail or track 313, the uprights of the output row 331 and a rail or track 318 running longitudinally along the top of the output row 331.

[0146] As discussed above with reference to Figures 8e and 8f, the rails or tracks 313, 318 may comprise longitudinally extending slotted extrusion members, and the retention mechanism comprises a gear or wheel mechanism captured within the slotted extension members up to the transfer point between the substantially vertically extending uprights of the output row and the substantially horizontal rails or tracks 313, 318. However, it will be appreciated that there are many ways known to those skilled in the art to achieve this objective. For example, the tracks or rails 313, 318 may not be slotted, but may be C-shaped in cross section, with the capture wheel mechanism held in place by the distal end of the C.

[0147] In this way, fewer shuttle devices 310 are required than the number of output queues 331 in the picking surface 118. For example, one shuttle device can cover ten or more output queues 331. However, the number of shuttle devices 310 required depends on the turnover rate of storage containers 10 at presentation positions 116.

[0148] In a further modified and simplified form of the embodiment described with reference to Figures 8g and 8h, a longitudinally extending rail or track 313 carries a plurality of shuttle devices 310 which are movable along the track 313 along the base of the output queue 331 which extends substantially parallel to the picking surface 118. The shuttle devices 310 comprise a lift device and a container receiving portion 132 which further comprises transport means.

[0149] In use, the storage container 10 is lowered onto the container receiving portion 132 by the load handling device 30. The shuttle device 310, under the control of the computer-controlled utility, is moved along the track 313 to the base of the output queue associated with the presentation portion 116 on which the storage container 116 is to be placed. Once in the appropriate position at the base of the associated output queue 131, 331, the lift device is activated to lift the storage portion 132 of the storage container 10 to the level of the predetermined presentation position 116. Once the storage container 10 is at the required level in the output queue 131, the transport means is activated to move the storage container 10 from the container receiving portion to the presentation position 116, the pre-picking storage position 126, or the additional storage position 128.

[0150] It will be appreciated that the transport means may be in any suitable form that fulfils the described functions and may be in the form of any of the transport mechanisms described above with reference to any of the other embodiments of the invention or its forms.

[0151] It will be apparent to one skilled in the art that there are many ways to achieve the above result and any suitable mechanism for achieving the objective can be envisioned.

[0152] Advantageously, with reference to all of the embodiments of Figures 7 and 8, in the event that a single shuttle device 310 or container lift device 300 fails, there will be another shuttle device 310 or container lift device 300 that can take over. Additionally, with reference to the simplified embodiment described above, the functioning shuttle device 310 can push or pull the failed shuttle device 310 out of the aisle. In this way, there is no single point of failure in replenishing the presentation positions 116 in the picking surface 118.

[0153] In an alternative to this embodiment, the storage locations 126 described with reference to the previous embodiment may be located between the container lift device 300 and the presentation positions 116. Such additional storage positions 126 may be provided on one or both sides of the container lift device 300.

[0154] Further aspects of the present invention are shown in Figures 9, 10 and 11. Items referenced in the systems described above in both the preamble and first and second embodiments of the present invention retain the same reference numerals. It will be appreciated that these aspects of the present invention can be combined with any or all of the above embodiments, and all alternatives referenced therein, to provide maximum flexibility in large scale CFC operations in online retail environments.

[0155] 9 illustrates a further aspect of the invention comprising a picking aisle 100 positioned within a grid-based storage area 102. In this aspect of the invention, the storage area 102 comprises separate areas 402a and 402b on either side of the picking aisle 100.

[0156] In all other respects, the storage area 402 is as described in any of the above embodiments.

[0157] Storage area 402a includes a storage area capable of pallet-sized storage. Load handling device 400 is sized and configured to be able to pick up, move, and place pallets of predetermined standard sizes adjacent picking aisle 100. Larger items, or items delivered to CFC by suppliers on pallets in large quantities, are stored in a specially configured grid-based system 402a.

[0158] In use, items required at a picking station 114 stored within storage area 402b are picked from the associated presentation portion 116, which has been delivered to the presentation position 116 in any of the ways described above.

[0159] In use, items stored in the pallet section of storage area 402a are treated similarly to storage area 402b, except that there is no presentation portion 116. Items or products placed on the pallet are delivered directly to the picking aisle 100, and workers 120 on the other side of the picking station 114 can disassemble the pallet and pick the items from the pallet to a temporary storage area (not shown) in the order assembly area 104. Such temporary locations at picking stations are described in Patent No. GB2,524,383, dated December 5, 2016 (Ocado Innovation Limited), which is incorporated herein by reference in its entirety.

[0160] Advantageously, the use of a pallet-sized grid-based storage system and storage area 402a allows items to be stored and accessed without a lengthy decant process required to break down the items and products on the pallet and place them into storage containers 10 and system 102. However, since not all items are delivered on pallets, both systems may be required and can be advantageously combined in the manner described above.

[0161] FIG. 10 illustrates a further embodiment of the present invention comprising a picking aisle 100 positioned within a grid-based storage area 102. In this embodiment of the present invention, the storage area 102 comprises distinct areas 502, 502a, and 502b, each distinct area comprising a distinct area of ​​the grid-based storage system separated by a divider or crash barrier 504. In this embodiment of the present invention, the distinct areas 502, 502a, and 502b contain storage containers 10, 10a, and 10b of different sizes. With reference to FIG. 10, the order picking system operates in exactly the same manner as described above with reference to the previous embodiment. The only difference is that the presentation positions are sized to accommodate storage containers 10 of different distinct sizes. It will be appreciated that in the example described herein, there are three sizes of storage containers 10, 10a, and 10b. Storage container 10 is a container of a similar size as those described above, storage container 10b has a footprint with a cross-sectional area of ​​an integer number of the size of storage container 10, and storage container 10b has the same footprint as storage container 10 but is taller. Again, these are just some of the sizes of storage container 10 that can be used, but it will be understood that this aspect of the invention is not limited to these sizes.

[0162] This form of storage system having a plurality of different sized robotic load handlers and storage containers 10 is described in UK Patent No. GB2,528,573B1, dated February 8, 2017 (Ocado Innovation Limited), the contents of which are incorporated herein by reference in their entirety.

[0163] In all other respects, the order picking system, and in particular the storage area 502 within the order picking system, operates in substantially the same manner as described above with reference to other embodiments of the present invention.

[0164] 11 illustrates a further aspect of the present invention in which multiple picking aisles 100 at different levels are served through a single grid-based storage system. Again, the order picking system operates in the same manner as described with reference to the above embodiment, and can include the alternatives and other examples discussed above.

[0165] However, to allow the robotic load handler 30 to place storage containers 10 at landing positions 132 on multiple levels, it is necessary to offset the presentation positions 616 on the first level relative to the presentation positions 616' on the second level.

[0166] Figures 12 and 13 illustrate further aspects of the invention in which a grid-based storage system is provided with conveyor-based picking aisles 100. In these aspects of the invention, the grid-based storage system picking stations 714 are provided within a CFC environment. With this in mind, Figure 12 illustrates an order picking system in which a zone picking area including picking aisles 100 is located on one side of the grid-based storage system.

[0167] The combination of zone picking, picking aisles 100, and grid-based storage system 102, as described in detail above, allows for fast-moving products and items to be handled within the zone picking area, and slower-moving items to be handled in the order assembly area at picking station 714. In picking station 714 according to one aspect of the invention, storage containers 10 containing items needed for a customer order and shipping containers DT designated for that particular customer order are placed at picking station 714. The needed item(s) are picked from storage container 10 into shipping container DT, which is then removed by load handling device 30 and placed back into stack 12 in storage area 102. The shipping container DT can remain at picking station 714 to await other items until all items needed for the same customer order have been transferred from the storage containers 10 delivered by the load handling device to shipping container DT.

[0168] Faster moving items, handled in the manner described above with reference to various embodiments of the present invention, are picked into shipping containers DT in zone picking aisles 100. The shipping containers DT are then placed in storage receptacles 10 as described above and entered into the storage system, and the entire customer order when assembled across multiple shipping containers DT is sequenced within the storage system for output in a single movement to a distribution area prepared and sorted for the requested delivery route.

[0169] It will be appreciated that empty storage containers 10, or storage containers 10 containing shipping containers DT, or storage containers containing shipping containers DT and bags 52 may all be stored in stacks 12 within storage area 102. Accordingly, any suitable means for placing such containers or combinations thereof may be used as described above. Alternatively, other forms of input will be apparent to those skilled in the art.

[0170] FIG. 13 illustrates a further configuration of a zonal picking system with a grid-based system. In this form of the invention, picking stations 714 of the grid-based system are located within the system adjacent to the zonal picking aisles. In this manner, faster-moving items and products handled in the zonal picking areas may be integrated with slower-moving items handled in the grid-based picking stations. A single worker 120 can pick from both areas. Alternatively, multiple workers can work in a single picking area to assemble a single customer order into a series of shipping containers DT at picking stations 714, which are then stored in storage receptacles 10 and entered into the storage system for sequencing and dispatch at the required time.

[0171] It will be appreciated that there may be many containers 10 in any given storage system, and that many different items may be stored in the containers 10 in the stacks 12, with each container 10 containing a different category of inventory item 28 within a single stack 12.

[0172] It should be noted that a shipping container DT may be an actual shipping container for onward transport to a customer, or may be a receptacle or container 10 with "to be picked later" items destined for delivery elsewhere, such as to an alternate fulfillment center. The term shipping container DT is used to distinguish a receptacle 10 from a shipping container DT.

[0173] It will also be understood that the delivery container DT may be contained within the vessel 10 when stored in a grid-based system to ensure that the robotic load handling device can handle all vessel or container movements, whether in the stacks 12 of the main storage system or in a small robotic picking area.

[0174] Additionally, the containers, receptacles, or totes used in any of the above-described embodiments of the present invention, as well as all forms and variations thereof, may be in a 180 degree "stack and nest" configuration, where rotating two similar containers 180 degrees relative to each other changes the stacking or nesting ability of the containers accordingly.

[0175] Additionally, embodiments of the present invention and all of its configurations have been described with reference to the use of an open-top container, receptacle, or tote. However, it will be recognized that any suitable configuration of container, receptacle, or tote may be used. For example, the container, receptacle, or tote may be provided with a lid (hinged or otherwise), side opening panels, end opening panels, or any other configuration suitable for the described purpose.

[0176] Furthermore, it will be understood that the storage container 10 need not be in the configuration shown in the accompanying drawings. The storage container 10 may have a rectangular footprint or a square footprint. Furthermore, the storage container 10 is shown in presentation position 116 with the short edge first to increase packing density of the container 10. However, a long edge first configuration is possible as well.

[0177] It will be understood that the load handling device described above may be in the form detailed in the specific embodiments and referenced drawings, however, any form of load handling device may be used, including but not limited to a load handling device with a cavity, a load handling device in a cantilever configuration, a shuttle, a gantry crane, or any other form of load handling device suitable for the described function.

[0178] Furthermore, while many of the above embodiments are described with reference to a remote or separate robotic picking area, it will be understood that the main storage system can be used as a robotic picking area such that it functions simultaneously as a conventional picking and storage system.

[0179] In all of the above embodiments, picking of items from storage receptacle 10 into delivery container DT may be done manually by a worker or robotically by a suitably controlled robotic picking device.

[0180] Furthermore, it will be understood that the picking operations described above need not only apply to picking customer orders, but that the picking operations may also be part of picking delivery containers DT, or other forms of containers, receptacles, or totes, for onward transfer to smaller CFCs within a CFC hierarchy, or as part of a supply or distribution network.

[0181] Additionally, while the above system has been described with respect to order picking within an online retail business, particularly an online grocery retail business, it will be appreciated that the system can also be used in other order picking systems. For example, general merchandise item picking is contemplated. Additionally, the described system can be used in other manufacturing environments that require regular access to large numbers of parts, for example, in an automotive or vehicle assembly line. The inventions described in the original claims of this application are set forth below. [1] A system for picking items from a storage facility, comprising: The system includes a grid-based storage system 102, 103; The storage system includes a series of storage containers 10; The storage container 10 contains the items to be stored; The storage containers 10 are positioned in a stack 12 within a framework 14, a portion of the framework 14 including at least one output column 131; the or each output queue is adapted to receive at least one storage container 10 removed from the storage system, and one of the output queues 131 is provided with a plurality of presentation positions; the storage container 10 is movable from a storage position within the stack 12 to the presentation position 116 away from the stack 12 via the or each output queue 131; the presentation positions 116 are arranged to position a plurality of storage containers 10 on at least one side of the storage system; The presentation positions 116 are positioned so that items stored in the storage containers 10 are accessible to an item picker. [2] The system further includes at least one load handling device 30 operable on the rail or track 22; The rails or tracks 22 are disposed on substantially horizontal members of the framework 14; the or each load handling device 30 includes a lift mechanism 38, 39 that engages at least one storage container 10 to lift the storage container 10 from the stack 12; The system of [1], wherein the load handling device 30 further includes a drive means for driving the load handling device 30 from a first position above the stack 12 of storage containers 10 to a second position above the output row 131, 331. [3] The system includes a plurality of output columns 131, 331; The output columns 131, 331 define a plurality of associated presentation positions 116; The system of any one of [1] to [2], wherein the presentation positions 116 associated with the plurality of output columns 131 together define an array of presentation positions 116 on at least one surface of the storage system. [4] The system described in any one of [1] to [3], wherein the output queue 131, 331 further includes a transport means for transporting the storage container 10 delivered to the load handling device 30 to the presentation position 116 associated with the output queue 131. [5] The transfer means includes a container lift device 300; [4] The system of [4], wherein the container lift device (300) is movable within the output queue (131, 331) between positions corresponding to the presentation positions (116). [6] The container lift device 300 includes a storage container 10 receiving portion 132; The system described in [5], wherein the container lift device 300 further includes a conveyor means adapted to transport a storage container 10 positioned on the storage portion 132 to a predetermined presentation position 116 within an array of presentation positions 116 on one side of the storage system. [7] The transport means includes a frame 340 carrying at least one shuttle device 310; The system according to [4], wherein the frames 340 are arranged in the plurality of output columns 131. [8] the frame 340 includes tracks 342, 344, 346 along which the or each shuttle device 310 can move; [7] The system described in [7], wherein the or each shuttle device 310 is movable around the tracks 342, 344, 346 to a position in the output row 131 that corresponds to a presentation position 116 in an array of presentation positions 116 on one face of the storage system. [9] The system of any one of [1] to [8], wherein the output array 131, 331 further includes sensor means for detecting the presence of a storage container 10 in the output array 131, 331 so as to prevent activation of the transfer means unless a storage container 10 is positioned on the storage container 10 receiving portion 132.

[10] The column 131 further includes a pre-picking position; A system described in any one of [3] to [9], wherein a storage container 10 positioned at the pre-picking position is transferred to the presentation position 116 by a further transport means on the storage container 10 being removed from the presentation position 116, thereby replenishing the presentation position 116 with storage containers 10 as needed.

[11] The system of any one of [4] to

[10] , wherein the transport means includes conveyor means.

[12] The system of

[11] , wherein the conveyor means comprises a roller conveyor or a belt conveyor.

[13] The system of

[11] or

[12] , wherein the conveyor means is driven.

[14] The system of [4], wherein the transfer means comprises a gravity-feed conveyor mechanism.

[15] The gravity-feed conveyor mechanism comprises a container-receiving portion 132; the container receiving portion includes a plurality of rotatably mounted rollers;

[14] The system described in

[14] , wherein when the container accommodating portion 132 rotates around a point on the output row 131, the rollers act to transfer the storage container on the container accommodating portion 132 to an adjacent storage position 126 in the output row 132 under the weight of the storage container 10.

[16] The system according to any one of [1] to

[15] , wherein the item picking system further includes an order assembly portion 104.

[17] The system of

[15] , wherein the order assembly portion 104 includes a conveyor system 106, 108 that carries delivery containers DT, onto which items are picked from the storage containers 10 in the presentation positions 116.

[18] The system according to

[15] , wherein the order assembly part includes a trolley carrying a delivery container DT, onto which items are picked from the storage container 10 in the presentation position 116.

[19] The system of any one of

[15] to

[17] , wherein a predetermined arrangement of presentation positions 116 is provided with associated order assembly portions 104.

[20] The system of

[18] , wherein the plurality of order assembly portions 104 are associated with a predetermined arrangement 118 of presentation positions 116.

[21] The system of any one of

[15] to

[19] , wherein the order assembly portions 104 are positioned across multiple levels of the storage system.

[22] The system of any one of [1] to

[21] , wherein the storage containers 10 removed from the presentation positions 116 are returned to the storage area 102 via a transfer means acting on the storage containers 10 to return them to the storage area 102.

[23] A system as described in any one of [1] to

[20] , wherein storage containers 10 removed from presentation positions 116 are manually collected by a worker and returned to the storage area at a location away from the presentation positions 116.

[24] The output train further includes a stop means 240; A system according to any one of [1] to

[23] , wherein the stop means is adapted to prevent movement of the storage container 10 from a storage position 126 in the output queue 131 to a presentation position 116, or from a storage position 128 to a storage position 126 in the output queue 131, 331.

[25] The system of

[24] , wherein the stop means 240 comprises a substantially L-shaped pivotally mounted member mounted below the conveyor means in the container receiving portion 132, and the presence of the storage container 10 on the container receiving portion 132 acts to pivot the member such that a distal end of the L-shaped member protrudes through the container receiving portion and prevents transfer of the storage container 10 to an adjacent position 126, 116.

[26] The load handling device comprises a cavity; The system according to any one of [2] to

[25] , wherein the cavity is adapted to accommodate a storage container 10.

[27] The system of

[26] , wherein the load handling device 30 occupies the footprint of a single grid space in the grid-based storage system.

[28] The system of any one of [2] to

[25] , wherein the load handling device comprises a cantilever-shaped body.

[29] The order picking system of any one of [1] to

[28] , wherein the storage area of ​​the grid-based storage system is adapted to store storage containers 10 of multiple sizes.

[30] The order picking system of

[29] , wherein the storage system includes a presentation position adapted to present storage containers of a size stored within the storage system.

[31] The order picking system of

[28] , wherein the storage area includes a grid-based storage system adapted to store containers 10 containing pallets.

[32] The items to be picked may be picked from a storage container 10 in a presentation position 116 or from an order assembly area 714 associated with the grid-based storage system; An order picking system as described in any one of [1] to

[31] , wherein the items in the storage container 10 at the presentation position 116 include items that are frequently picked in the context of an online retail system.

[33] An order picking system or a system for picking items from a storage system according to any one of [1] to

[32] , wherein the system is provided with a computer control utility for controlling the position and movement of storage containers 10 within the system.

[34] The system of any one of [1] to

[33] , wherein the items to be picked are picked from the storage container 10 into the delivery container DT by a robot or manually.

[35] The system described in any one of [1] to

[34] , wherein the shipping container DT is stored in a storage container 10.

[36] The system of any one of [1] to

[35] , wherein the storage area includes a storage container containing the items to be picked, and / or a delivery container DT, and / or a storage container 10 containing a delivery container DT, and / or a delivery container DT containing a customer order to be partially or completely picked.

[37] A method comprising: A method for picking items in an online retail system within an item picking system according to any one of [1] to

[36] .

Claims

1. A storage system comprising a frame structure (14), the frame structure (14) defining a plurality of storage rows for storing storage containers (10) arranged in stacks (12), a plurality of upright members (16) further defining a plurality of output rows arranged in the rows; a horizontal lattice structure supported from below by said plurality of upright members (16), said horizontal lattice structure comprising a plurality of rails or tracks (22) arranged in a lattice pattern over said storage rows and said output rows (331) to allow load handling devices operating on the rails or tracks (22) to move from said storage rows of said plurality of storage rows to said output rows (331); a load handling device (30) operable to move on the horizontal grid structure, the load handling device (30) comprising drive means for driving the load handling device (30) from a first position above a storage row of the plurality of storage rows to a second position above an output row of the plurality of output rows (331), the load handling device (30) further comprising lift mechanisms (38, 39) configured to engage and lift a storage container (10) from a stack (12) in the storage row in the first position and to lower and release the storage container (10) into the output row (331) in the second position; a shuttle device (310) configured to move horizontally between the plurality of output rows (331) and vertically within each output row (331), and further configured to accommodate a storage container (10) to be lowered into an output row (331) of the plurality of output rows; a storage system, wherein each output queue (331) comprises a plurality of presentation positions (116) for presenting storage containers (10) so that items stored in the storage containers (10) are accessible to item pickers, and wherein the shuttle device (310) is configured to pause at a level corresponding to any one of the plurality of presentation positions (116) so that the shuttle device (310) can move a storage container accommodated on the shuttle device (310) to any one of the presentation positions (116) of a particular output queue (331).

2. The system further comprises a frame interposed between the upright members (16) of the plurality of output rows (331), the frame comprising: a substantially horizontal first track portion (342) along the base of the plurality of output rows (331); a substantially horizontal second track section (344) extending along the underside of said plurality of rails or tracks (22); a plurality of substantially vertical track sections (346) linking said first track portion (342) and said second track portion (344), wherein the pitch of the vertical track sections (346) substantially matches the pitch of the upright members of said plurality of output trains (331); 2. The storage system of claim 1, wherein the shuttle device (310) is configured to move along the first track portion (342) and the second track portion (344) to move horizontally between the plurality of output rows (331), and along the vertical track section (346) to move vertically within each output row (331).

3. 3. The storage system of claim 2, wherein the shuttle device (310) is configured to be captured and moveable along, within, or on the first track portion (342), the second track portion (344), and the vertical track section (346).

4. 4. The storage system of claim 3, wherein the first track portion (342) and the second track portion (344) are linked to the vertical track section (346) by a joint configured to enable a movement mechanism of the shuttle device (310) to move from the vertical track section (346) to the first track portion (342), from the vertical track section (346) to the second track portion (344), and vice versa.

5. a substantially horizontal first shuttle rail or track (313) extending along the base of the uprights (16) of said output rows (331), wherein said shuttle device (310) is configured to move along said first shuttle rail or track (313) to move horizontally between said output rows (331); 2. The storage system of claim 1, further comprising: climbing means (316) configured to allow the shuttle device (310) to move vertically within each output row (331).

6. 6. The storage system of claim 5, further comprising a substantially horizontal second shuttle rail or track (318) extending along the top of the output row and below the underside of the plurality of rails or tracks (22), wherein the shuttle device (310) is configured to move along the second shuttle rail or track (318) to move horizontally between the output rows (331).

7. 7. A storage system according to claim 5 or 6, wherein the shuttle device (310) comprises the climbing means (316), the climbing means (316) being configured to engage the uprights (16) of each output row (331) so as to move the shuttle device (310) vertically within each output row (331).

8. 8. The storage system of claim 1, wherein the shuttle device (310) comprises a section of a conveyor (333) for accommodating storage containers lowered to an output row (331) of the plurality of output rows (331).

9. The storage system of any one of claims 1 to 8, comprising a plurality of shuttle devices (310).

10. 10. The storage system of claim 9, wherein the number of shuttle devices (310) is less than the number of output queues (331).

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