Storage and Retrieval Systems

Abstract

To increase the amount of handling of a system for storage and take-out.SOLUTION: An automatic system for storage and take-out comprises an autonomous carrier vehicle 110, a transfer deck 130B to define a transport face for a vehicle, and first and second pick-face interface stations. Each station forms pick-face transfer to interact between a vehicle at a deck and a lift in each station such that a pick face can be transferred between the lift and the vehicle in each station. The vehicle is configured to take out a first pick face at a first station, go and come to the deck, and buffer the first pick face or at least part thereof at a second station such that the second station has a plurality of pick faces to be buffered at a common support portion in an order sequence of the pick faces according to a predetermined case-unloading order sequence of mixed-cases pick faces.SELECTED DRAWING: Figure 3B

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application is a nonprovisional application of and claims the benefit of U.S. Provisional Patent Application No. 62 / 104,520, filed January 16, 2015, the disclosure of which is incorporated herein by reference in its entirety.

[0002] This application is also related to U.S. Patent Application No. 14 / 966,978, filed December 11, 2015, U.S. Patent Application No. 14 / 997,892, filed January 18, 2016, U.S. Patent Application No. 14 / 997,902, filed January 18, 2016, U.S. Patent Application No. 14 / 997,925, filed January 18, 2016, and U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, the disclosures of which are incorporated herein by reference in their entireties.

[0003] [Technical field] FIELD The exemplary embodiments relate generally to material processing systems, and more particularly to the transport and storage of items within material processing systems. [Background technology]

[0004] Multi-level storage and retrieval systems may be used in warehouses for the storage and retrieval of goods. Generally, goods are transported into and out of the storage structure by vehicles including lifts for transfer to vehicles on the storage level, vehicles that travel up ramps to a given storage level, or vehicles that travel along guideways. Goods stored in the storage and retrieval system are generally stored in storage spaces on each storage level, and transport vehicles located on that storage level have access to one level of the storage space. Generally, lifts that transfer items to and from storage spaces and transport vehicles between different storage levels are built into the vehicles (such as by gantry cranes) or have a paternoster configuration in which the lift's loading shelves continuously cycle around a frame at a predetermined speed.

[0005] Case units removed from the multi-level storage and retrieval system are transported to a packaging station where the case units are placed onto pallets for delivery. Generally, pallets contain similarly sized and shaped case units, so that stable case levels, sometimes with corrugated cardboard sheets between levels, are formed on the pallet. In some instances, each level of a pallet tier is formed separately and then placed onto the pallet to form a stacked tier. Mixed pallets are also possible. Generally, to form a pallet tier, cases are positioned at a buffer station or other location on the pallet loading station so that the case dimensions are measured. A computer or other processor determines the case placement based on the dimensions and directs a robot to remove the cases for placement on the pallet tier. Summary of the Invention

[0006] To increase the throughput of a storage and retrieval system, it may be advantageous to sort the case units for placement on pallets during transport of the case units from the storage structure of the storage and retrieval system. [Brief explanation of the drawings]

[0007] The above aspects and other features of the disclosed embodiments are explained in the following description taken in conjunction with the accompanying drawings.

[0008] [Figure 1] 1 is a schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1A] 1 is a schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1B] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1C] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1D] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1E] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1F] 1 is a schematic illustration of a mixed pallet load formed by an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 1G] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 2A] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 2B] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 3A] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 3B] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 4A] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 4B]1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 5] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 6] 1 is a schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 6A] 1 is a schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 7] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 8] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 9] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 10] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10A] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10B] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10C] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10D] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 10E] 1 is a partial schematic illustration of a transport vehicle in accordance with aspects of the disclosed embodiment; [Figure 11] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 12] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 13] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 14] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 15]FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 16] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 17] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 18] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 19] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 20] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 21] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 22A] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 22B] 1 is a partial schematic illustration of an automated storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 23] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 24] 1 is a partial schematic illustration of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 25] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; [Figure 26] FIG. 10 is a schematic illustration of an operator station of a storage and retrieval system in accordance with aspects of the disclosed embodiment; [Figure 27] FIG. 10 is an exemplary flow diagram according to aspects of the disclosed embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0009] 1 is a schematic diagram of an automated storage and retrieval system 100 in accordance with aspects of the disclosed embodiment. Although aspects of the disclosed embodiment will be described with reference to the drawings, it should be understood that aspects of the disclosed embodiment can be embodied in many forms. Additionally, any suitable size, shape, or type of elements or materials may be used.

[0010] According to aspects of the disclosed embodiment, the automated storage and retrieval system 100 may operate in a retail distribution center or warehouse to fulfill orders received from retail stores for case units, such as those described in U.S. Patent Application No. 13 / 326,674, filed December 15, 2011, the entire disclosure of which is incorporated herein by reference. For example, a case unit is a case or unit of goods that is not stored (e.g., uncontained) in a tray, on a tote, or on a pallet. In another example, a case unit is a case or unit of goods that is contained in any suitable manner, such as in a tray, on a tote, or on a pallet. In yet another example, a case unit is a combination of uncontained and contained items. It is noted that a case unit may include, for example, a boxed unit of goods (e.g., a case of soup cans, a box of cereal, etc.) or an individual item adapted to be picked from or placed on a pallet. According to aspects of the disclosed embodiment, shipping cases for case units (e.g., cartons, barrels, boxes, crates, jugs, or any other device suitable for holding case units) may be variable in size, may be used to hold case units in delivery, and may be configured to be palletizable for delivery. Note, for example, that when a batch of case units or pallets arrive at a storage and retrieval system, the contents of each pallet may be identical (e.g., each pallet holds a predetermined number of identical items—one pallet holds soup, another pallet holds cereal), and when the pallets leave the storage and retrieval system, the pallets may contain an appropriate number and combination of different case units that are fed, for example, to a palletizer in an assorted arrangement to form mixed pallets (e.g., mixed pallets, each mixed pallet holds a different type of case unit—one pallet holds a combination of soup and cereal).In embodiments, the storage and retrieval systems described herein may be applied to any environment in which case units are stored and retrieved.

[0011] 1F , it is noted that, for example, when incoming batches or pallets (e.g., from a case unit manufacturer or wholesaler) arrive at the storage and retrieval system 100 for replenishment, the contents of each pallet may be identical (e.g., each pallet holds a predetermined number of identical items—one pallet holds soup, another pallet holds cereal). As can be appreciated, the cases in such a pallet load may be substantially similar, in other words, homogeneous cases (e.g., similar dimensions) and may have identical SKUs (alternatively, as discussed above, the pallet may be a “rainbow” pallet with layers of homogeneous cases). When the pallet PAL leaves the storage and retrieval system 100 with cases fulfilling the replenishment order, the pallet PAL may include any suitable number and combination of different case units CU (e.g., each pallet may hold a different type of case unit—one pallet may hold a combination of canned soup, cereal, drink cartons, cosmetics, and household cleaners). Cases combined on a single pallet may have different dimensions and / or different SKUs. In one aspect of the exemplary embodiment, storage and retrieval system 100 may be generally configured to include an inbound section, a storage and sortation section (in one aspect, storage of items is optional), and an outbound section, as described in further detail below. As can be appreciated, in one aspect of the disclosed embodiment, system 100, operating as, for example, a retail distribution center, may function to receive a single pallet load of cases, break down the goods on the pallet from the single pallet load into separate case units that are individually operated by the system, or separate the cases, remove and sort the different cases required by each order into corresponding groups, transport the corresponding groups of cases, and assemble them into what may be referred to as a mixed case pallet load MPL.As can be appreciated, as shown in FIG. 26, in one aspect of the disclosed embodiment, system 100, operating as, for example, a retail distribution center, may function to receive a single pallet load of cases, break down the goods on the pallet from the single pallet load into independent case units that are individually operated by the system, or separate the cases, remove and sort the different cases required by each order into corresponding groups, transport the corresponding groups of cases, and sequence the corresponding groups of cases (in a manner described herein) at operator station 160EP, where items removed from different case units CU and / or the different case units CU themselves are placed by operator 1500 or any suitable automation into one or more bags, totes, or other suitable containers TOT in a predetermined order sequence of the items to be removed, for example, according to instructions to fulfill one or more customer orders, where the case units CU are sequenced at operator station 160EP according to the predetermined order sequence, and it is noted that the sequencing of case units CU described herein results in the sequencing of case units CU at operator station 160EP. The inbound section may generally be capable of breaking down a single pallet load into individual cases and transporting the cases via appropriate transports for delivery to the storage and sortation section. In other aspects, the outbound section assembles the appropriate group of ordered case units, which may vary in SKU, size, etc. (e.g., to fulfill a customer order), into bags, totes, or other suitable containers according to a predetermined order sequence of the items to be removed.

[0012] The storage and sortation section includes a multi-level automated storage array having a transport system that sequentially receives individual cases for storage in a storage area and feeds the individual cases into the multi-level storage array, as described in further detail below. The storage and sortation section also defines the outbound transport of case units from the multi-level storage array, such that desired case units are individually removed according to instructions generated in response to orders entered into a warehouse management system, such as warehouse management system 2500, for transport to the output section. In other embodiments, the storage and sortation section receives individual cases, sorts the individual cases (e.g., utilizing buffers and interface stations described herein), and transports the individual cases to the output section according to orders entered into the warehouse management system. The sorting and grouping of cases according to orders (e.g., order output sequence) may be performed in whole or in part by either the storage and retrieval section or the output section, or both, and the boundary therebetween is one for convenience of explanation, and the sorting and grouping can be performed in numerous ways. The intended result is that the output section will assemble the appropriate group of ordered cases, which may vary in SKU, size, etc., into a mixed case pallet load, for example, in the manner described in U.S. Patent Application No. 13 / 654,293, filed October 17, 2012 (now U.S. Patent No. 8,965,559), the entire disclosure of which is incorporated herein by reference.

[0013] In an exemplary embodiment, the discharge section produces a pallet load in what may be referred to as an organized structure of mixed case stacks. The organized structure of the pallet load described herein is exemplary, and in other aspects, the pallet load may have any other suitable configuration. For example, the organized structure may be any suitable predetermined configuration, such as a truck load or other suitable container, or a frame of a load container for holding a structural load. The organized structure of the pallet load may be characterized as having several flat case layers L121-L125, L12T, at least one of which is formed from a plurality of non-intersecting, freestanding, and stable mixed case stacks. The mixed case stacks of a given layer may have substantially the same height to form top and bottom surfaces of the given layer that may be recognized as substantially flat, and may be in sufficient number to cover the pallet area or a desired portion of the pallet area. The overlying layers may be oriented so that the cases of the corresponding layer straddle the stacks of the supporting layers, thus stabilizing the stack and, accordingly, stabilizing the boundary layers of the pallet load. In defining the pallet load into an organized layer structure, the interlocking 3-D pallet load solution is decomposed into two parts that can be stored separately: a vertical (1-D) part that decomposes the load into layers, and a horizontal (2-D) part that efficiently distributes equal-height stacks to fill the pallet height of each layer. As described below, the storage and retrieval system delivers case units to the output section as the two parts of the 3-D pallet load solution are decomposed. The predetermined configuration of the mixed pallet load determines the order of the case units and whether the case units provided by the sorting and output section to the load building system (which may be automated or manual loading) are single case unit pick faces or combined case unit pick faces.

[0014] According to aspects of the disclosed embodiment, and referring again to FIG. 1, the automated storage and retrieval system 100 includes an input station 160IN (including a depalletizer 160PA and / or conveyor 160CA that transports items to the lift module for entry into the storage section), an output station 160UT (including a palletizer 160PB, operator station 160EP, and / or conveyor 160CB that transports case units from the lift module for removal from the storage section), input and output vertical lift modules 150A, 150B (generally referred to as lift modules 150; although input and output lift modules are illustrated, a single lift module may be used to both transport case units into and remove case units from the storage structure), a storage structure 130, and a number of unmanned rovers or transport vehicles 110 (referred to herein as "bots"). Note that depalletizer 160PA may be configured to remove case units from pallets so that loading station 160IN may transport the items to lift module 150 for loading into storage structure 130. Palletizer 160PB may be configured to place items removed from storage structure 130 onto pallets PAL (FIG. 1F) for delivery. As used herein, the lift module 150, storage structure 130 and bot 110 may be collectively referred to herein as the above-mentioned multi-level automated storage array (e.g., storage and sorting section) for defining (e.g., three-dimensional) transport / processing axes (e.g., relative to the reference coordinate system REF of bot 110 (FIG. 6) or any other suitable reference coordinate system of the storage and retrieval system) that provide a three-dimensional multi-level automated storage array, each processing axis having integral "on the fly" sorting (e.g., sorting of case units while the case units are being transported), such that sorting and processing of case units occurs substantially simultaneously without the need for dedicated sorters, as described in more detail below.Because sorting along each processing axis is selectable, load egress (e.g., transfer of outgoing case units to form palletized loads) can occur along all processing axes or along any combination of processing axes without the substantial processing costs associated with processing case units without sorting at all (e.g., "no sort" processing). As an example of processing case units with sorting, and referring also to FIG. 1A, storage and retrieval system 100 includes several processing areas or zones. For example, there are multi-level case unit storage processes 130LTP (e.g., placing case units into storage), horizontal case unit transport processes 110TP (e.g., transporting case units from storage along removal aisles and transfer decks), case buffer processes BTSTP (e.g., buffering case units to facilitate transport of case units between storage and vertical transport), vertical transport processes 150TP (e.g., transporting case units by vertical lift), and processes at output station 160TP including, for example, transport by conveyor 160CB and palletizing by palletizer 160PB. In one aspect, the classification of case units described herein is effected substantially simultaneously (e.g., "on the fly") with the processing of case units 130LTP, 110TP, BTSTP, 150TP along each processing axis (e.g., X, Y, Z axes relative to the reference coordinate system of the bot 110 and / or lift 150), and the classification along each axis is independently selectable such that classification is effected along one or more of the X, Y, Z axes.

[0015] As can be appreciated, in one aspect, on-the-fly sorting of case units occurs on the bot 110 without unloading the case units / pick faces carried by the bot 110, whether the bot 110 is moving between case unit / pick face holding locations or is static / immobile (e.g., not traversing a transfer deck, pick aisle, etc.). As described below, one or more of the high-density multi-level shelf aisles, linear buffer stations BS along the transfer deck 130B, and linear multi-location transfer stations TS provide on-the-fly sorting substantially simultaneous with processing along the X-axis. As also described below, one or more of the transfer arm and end effector 110PA of the bot 110 (the transfer arm and end effector 110PA of the bot 110 are configured to sort cases / pick faces through movement of the end effector along the Y axis for multiple independent pick-up / placement of cases / pick faces, the Y axis being defined by extension of the transfer arm 110PA and in a direction angled relative to another of the transport axes defined by the bot 110 along the pick-up path 130A), and the independent load handling device of the lift 150 (configured for sorting on the lift's platform through extension of the load handling device along the Y axis) provide on-the-fly sorting substantially simultaneous with processing along the Y axis. As can be appreciated, the lift 150 is configured to transport pick faces between different transfer deck levels and provide on-the-fly sorting substantially simultaneous with processing along the Z axis (defined by the lift 150) as described herein. In one embodiment, the lift is configured to retrieve one or more pick faces from one or more transfer deck levels and transport the one or more pick faces to a load filling section or cell (such as unloading station 160UT) of storage and retrieval system 100.Load filling section or load filling cell (used interchangeably herein and generally referred to as load filling) refers to either a palletized load filling section / cell (such as for producing mixed palletized loads MPL) or an item-specific load filling section / cell as described with respect to FIG. 26.

[0016] 1G and 2A, the storage structure 130 may include a plurality of storage rack modules RM comprised of a high-density three-dimensional rack array RMA accessible from a storage or deck level 130L. As used herein, the term "high-density three-dimensional rack array" refers to a three-dimensional rack array RMA having non-deterministic open shelves distributed along the retrieval aisle 130A, with the stacked shelves accessible from a common retrieval aisle travel plane or retrieval aisle level (e.g., case units are positioned at each retrieval aisle level within dynamically allocated storage space such that the vertical space / gap VG and horizontal space / gap G between case units are minimized at each retrieval aisle level, as described in further detail below).

[0017] Each storage level 130L includes a pick-face storage / handover space 130S (referred to herein as a storage space 130S) formed by rack modules RM, which, for example, include shelves arranged along a storage or retrieval aisle 130A (connected to the transfer deck 130B) that extends linearly through the rack module array RMA and provides access for the bot 110 to the storage space 130S and the transfer deck 130B. In one embodiment, the shelves of the rack modules RM are arranged as multi-level shelves distributed along the retrieval aisle 130A. As can be understood, to transfer a case unit between any of the storage spaces 130S of the storage structure 130 (e.g., on the level on which the bot 110 is located) and any of the lift modules 150, the bot 110 moves on the respective storage level 130L along the retrieval aisle 130A and the transfer deck 130B (e.g., each bot 110 has access to each storage space 130S on each level and each lift module 150 on each storage level 130L). The transfer decks 130B may be stacked one above the other or may be horizontally offset and positioned at different levels (corresponding to each level 130L of the storage and retrieval system), such as having one transfer deck 130B at one end or side RMAE1 of the storage rack array RMA, or at several ends or sides RMAE1, RMAE2 of the storage rack array RMA, as described in U.S. patent application Ser. No. 13 / 326,674, filed December 15, 2011, the entire disclosure of which is incorporated herein by reference.

[0018] The transfer deck 130B is substantially open and configured for non-deterministic movement of bots 110 across and along the transfer deck 130B along multiple movement lanes (e.g., along the X processing axis relative to the bot reference frame REF shown in FIG. 6). As can be seen, the transfer deck 130B of each storage level 130L communicates with each of the retrieval aisles 130A on the respective storage level 130L. The bot 110 moves along the retrieval aisles 130A (e.g., along the X processing axis relative to the bot's reference coordinate system REF shown in FIG. 6 ) and travels bidirectionally between the transfer deck 130B and the retrieval aisles 130A on each storage level 130L to access storage spaces 130S located on rack shelves parallel to each of the retrieval aisles 130A. (For example, as the bot 110 travels down each retrieval aisle 130A, it may access storage spaces 130S distributed on both sides of each aisle along the Y processing axis, such that the bots may have different opposing faces, e.g., with the drive wheels 202 leading the direction of movement or the drive wheels following the direction of movement, referring to FIG. 6 .) As can be understood, retrieval processing from the storage array in the horizontal plane corresponding to a given storage or deck level 130L is brought about by and manifests itself in combined or integrated processing along both the X and Y processing axes. As described above, the transfer deck 130B provides access for the bot 110 to each of the lifts 150 on each storage level 130L, the lifts 150 load and unload case units (e.g., along the Z processing axis) to and / or from each storage level 130L, and the bot 110 provides transport of case units between the lifts 150 and the storage space 130S.

[0019] As mentioned above, and referring also to FIG. 2A, in one embodiment, the storage structure 130 includes a plurality of storage rack modules RM configured in a three-dimensional array RMA, the racks arranged in an aisle 130A, which is configured for movement of the bot 110 within the aisle 130A. The transfer deck 130B has a non-deterministic transport surface along which the bot 110 moves, and the non-deterministic transport surface 130BS has two or more juxtaposed movement lanes (e.g., high-speed bot movement paths HSTP) connecting to the aisle 130A. As can be seen, the juxtaposed movement lanes are juxtaposed along the common non-deterministic transport surface 130BS between both sides 130BD1, 130BD2 of the transfer deck 130B. 2A , in one embodiment, aisle 130A is coupled to transfer deck 130B at one side 130BD2 of transfer deck 130B, while in other embodiments, aisle 130A is coupled to two or more sides 130BD1, 130BD2 of transfer deck 130B in a manner substantially similar to that described in U.S. patent application Ser. No. 13 / 326,674, filed December 15, 2011, the entire disclosure of which is already incorporated herein by reference. As described in further detail below, the other side 130BD1 of transfer deck 130B includes deck storage racks (e.g., interface station TS and buffer station BS) distributed along the other side 130BD1 of transfer deck 130B such that at least a portion of the transfer deck is interposed between the deck storage racks (e.g., buffer station BS or transfer station TS) and aisle 130A. The deck storage rack is positioned along the other side 130BD1 of the transfer deck 130B so as to communicate with the bot 110 from the transfer deck 130B and with the lift module 150 (e.g., the deck storage rack is accessed by the bot 110 from the transfer deck 130B and by the lift 150 to retrieve and place pick faces so that pick faces can be transferred between the bot 110 and the deck storage rack, and between the deck storage rack and the lift 150, and thus between the bot 110 and the lift 150).

[0020] Referring again to FIG. 1, each storage level 130L may include a charging station 130C for charging the onboard power supply of the bot 110 on that storage level 130L, as described, for example, in U.S. patent application Ser. No. 14 / 209,086, filed March 13, 2014, and U.S. patent application Ser. No. 13 / 326,823, filed December 15, 2011 (now U.S. Patent No. 9,082,112), the disclosures of which are incorporated herein by reference in their entireties.

[0021] Bot 110 may be any suitable independently operable autonomous guided vehicle that carries and transports case units along the X and Y processing axes throughout storage and retrieval system 100. In one embodiment, bot 110 is an automated, independent (e.g., free-riding) autonomous guided vehicle. Suitable examples of bots are described in U.S. patent application Ser. No. 13 / 326,674, filed December 15, 2011; U.S. patent application Ser. No. 12 / 757,312, filed April 9, 2010 (now U.S. Patent No. 8,425,173); U.S. patent application Ser. No. 13 / 326,423, filed December 15, 2011; U.S. patent application Ser. No. 13 / 326,447, filed December 15, 2011 (now U.S. Patent No. 8,965,619); U.S. patent application Ser. No. 13 / 326,448, filed December 15, 2011 (now U.S. Patent No. 8,965,619); U.S. patent application Ser. No. 13 / 326,674, filed December 15, 2011; U.S. patent application Ser. No. 13 / 326,674, filed December 15, 2011 (now U.S. Patent No. 8,425,173); U.S. patent application Ser. No. 13 / 326,423, filed December 15, 2011; U.S. patent application Ser. No. 13 / 326,447, filed December 15, 2011 (now U.S. Patent No. 8,965,619); U.S. patent application Ser. No. 13 / 326,448, filed December 15, 2011 (now U.S. Patent No. 8,965,619); U.S. patent application Ser. No. 13 / 326,674; No. 13 / 326,505 (now U.S. Patent No. 8,696,010), U.S. Patent Application No. 13 / 327,040 (now U.S. Patent No. 9,187,244), filed December 15, 2011, U.S. Patent Application No. 13 / 326,952, filed December 15, 2011, U.S. Patent Application No. 13 / 326,993, filed December 15, 2011, U.S. Patent Application No. 14 / 486,008, filed September 15, 2014, and U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015. Bot 110 (described in further detail below) may be configured to place case units, such as the retail items described above, into one or more levels of pick-up storage in storage structure 130 and then selectively pick up the ordered case units. As can be appreciated, in one embodiment, the processing axes X and Y (e.g., pick face transport axes) of the storage array are defined by pick-up aisle 130A, at least one transfer deck 130B, bot 110, and the bot's extendable end effector (as described herein) (and in other embodiments, the extendable end effector of lift 150 also at least partially defines processing axis Y).Pick faces are transported between an input section of the storage and retrieval system 100 (e.g., input station 160IN, etc.), where input of pick faces into the array occurs, and a load fill section of the storage and retrieval system 100 (e.g., output station 160UT, etc.), where output pick faces from the array are positioned to fill the load according to a predetermined load fill order sequence. In one embodiment, the storage rack module RM and the bot 110 are arranged in combination to provide on-the-fly sorting of mixed case pick faces simultaneously with transport in at least one of the processing axes (or in other embodiments, at least one of each of two or more) so that two or more pick faces are retrieved from one or more of the storage spaces and placed in one or more pick face holding locations (e.g., buffer station BS and transfer station TS, etc.) different from the storage space 130S according to a predetermined load fill order sequence.

[0022] The bots 110, lift modules 150, and other suitable features of the storage and retrieval system 100 are controlled in any suitable manner, such as, for example, by one or more central system control computers (e.g., control server) 120, through any suitable network 180. In one embodiment, the network 180 is a wired network, a wireless network, or a combination of wired and wireless networks, using any suitable type and / or number of communication protocols. In one embodiment, the control server 120 includes a collection of substantially concurrently executing programs (e.g., system management software) for substantially automatic control of the automated storage and retrieval system 100. For example, the collection of substantially concurrently executing programs configured to manage the storage and retrieval system 100 may include, by way of example only, controlling, scheduling, and monitoring the activity of all active system components; managing inventory (e.g., which case units are loaded and removed, the order in which the case units are removed, and where the case units are stored) and pick faces (e.g., one or more case units that are movable as a unit and manipulated as a unit by the components of the storage and retrieval system); and connecting with a warehouse management system 2500. Control server 120, in one aspect, may be configured to control features of the storage and retrieval system in the manner described herein. For simplicity and ease of explanation, the term "case unit" is used generally herein to refer to both individual case units and pick faces (where a pick face is formed from multiple cases that are moved as a unit).

[0023] 1B and 1D, the rack module array RMA of the storage structure 130 includes vertical support members 1212 and horizontal support members 1200 that define a high-density automated storage array, as described in further detail below. For example, in the retrieval aisle 130A, rails 1200S may be attached to one or more of the vertical and horizontal support members 1212, 1200, and the rails 1200S may be configured to allow the bot 110 to ride along the rails 1200S through the retrieval aisle 130A. At least one side of at least one of the retrieval aisles 130A of at least one storage level 130L may have one or more storage shelves (e.g., formed by rails 1210, 1200 and slats 1210S) provided at different heights to form multiple shelf levels 130LS1-130LS4 between the storage or deck levels 130L defined by the transfer deck 130B (and rails 1200S forming the aisle deck). Thus, there are multiple rack shelf levels 130LS1-130LS4 corresponding to each storage level 130L extending along one or more retrieval aisles 130A that communicate with the transfer deck 130B of the respective storage level 130L. As can be seen, the multiple rack shelf levels 130LS1-130LS4 result in each storage level 130L having a stack of stored case units (or layers of cases) accessible from a common deck 1200S of the respective storage level 130L (e.g., stacks of stored cases are disposed between the storage levels).

[0024] As can be seen, a bot 110 traversing the retrieval aisle 130A at a corresponding storage level 130L has access to each storage space 130S available on each shelf level 130LS1-130LS4 (e.g., to retrieve and place case units), with each shelf level 130LS1-130LS4 disposed between adjacent vertically stacked storage levels 130L on one or more sides PAS1, PAS2 (see, e.g., FIG. 2A) of the retrieval aisle 130A. As noted above, each of the storage shelf levels 130LS1-130LS4 is accessible by a bot 110 from rails 1200 (e.g., from a common retrieval aisle deck 1200S corresponding to the transfer deck 130B on the respective storage level 130L). 1B and 1D, there are one or more intermediate shelf rails 1210 spaced vertically (e.g., in the Z direction) from one another (and from rail 1200) to form multiple stacked storage spaces 130S, each accessible by bot 110 from a common rail 1200S. As can be appreciated, horizontal support members 1200 also form shelf rails (in addition to shelf rails 1210) on which case units are placed.

[0025] Each stacked shelf level 130LS1-130LS4 (and / or each individual shelf level, as described below) of the corresponding storage level 130L defines an open, non-deterministic, two-dimensional storage surface (e.g., having a case unit support surface CUSP, as shown in FIG. 1D ) that facilitates dynamic allocation of pick faces both longitudinally (e.g., along the length of an aisle or aligned with the bot travel path defined by a picking aisle) and laterally (e.g., across the aisle or bot travel path relative to the depth of the rack). Dynamic allocation of pick faces and the case units that make up the pick faces is provided, for example, by methods described in U.S. Patent No. 8,594,835, issued November 26, 2013, the disclosure of which is incorporated herein by reference in its entirety. For example, a controller, such as controller 120, monitors the case units stored on the shelf and the empty spaces or storage locations between the case units. Empty storage locations are dynamically allocated, by way of example only, so that one case having a first size is replaced by three cases each having a second size that, when combined, fit into the space previously reserved for the first size case, or vice versa. Dynamic allocation substantially continuously changes the size of empty storage locations as case units are placed on and removed from the storage shelves (e.g., storage locations do not have predetermined sizes and / or locations on the storage shelves). In this manner, pick faces of case units (or totes) of variable length and width are placed into respective two-dimensional storage locations on the storage shelves (e.g., on each storage shelf level 130LS1-130LS4) with minimal gap G between adjacent stored case units / storage spaces (e.g., resulting in removal / placement of case units without contact with other case units stored on the shelf, see FIG. 1B).

[0026] As mentioned above, the spacing between rails 1200, 1210 (e.g., storage shelves) is variable to minimize the vertical gap VG between vertically stacked case units (e.g., provide sufficient clearance for insertion and removal of case units into and from their respective storage locations). As described below (e.g., with respect to sections SECA and SECB of FIGS. 1B and 2A ), in one embodiment, the vertical spacing between rails 1200, 1210 varies along the length of each retrieval aisle 130A, while in other embodiments, the spacing between rails 1200, 1210 may be substantially continuous along retrieval aisle 130A. It will be understood, and as described in further detail below, that the spacing between rails 1200, 1210 on one side PAS1 ( FIG. 2A ) of retrieval aisle 130A may be different from the spacing between rails 1200, 1210 on the opposite side PAS2 ( FIG. 2A ) of the same retrieval aisle 130A. As can be appreciated, any suitable number of shelves 1210 may be provided between decks 1200S of adjacent vertically stacked storage levels 130L, with the shelves having the same or different pitch between them (e.g., see FIG. 1C , where case units CUD1, CUD2, CUE1-CUE3, CUF1, CUF2 are arranged in vertical stacks on one side of the retrieval aisle, and case units CUA, CUB, CUC are arranged in vertical stacks on the other side of the retrieval aisle on storage shelves having substantially similar pitch). In one aspect of the disclosed embodiment, and referring to FIG. 1B , the vertical pitch between rack shelf levels 130LS1-130LS4 (corresponding to each storage level 130L) is varied so that the heights Z1A-Z1E between the shelves are different rather than equal, for example, to minimize the vertical gap V between the upper surface or top face CUTS of case unit CU and the bottom of the storage shelf 1200, 1210 directly above the case unit.As can be seen in FIG. 1B , minimizing gaps G and VG in both horizontal and vertical directions results in the arrangement of densely packed case units within storage shelves to form a dense three-dimensional rack array RMA. For example, dense multi-level shelf aisles increase throughput along the X processing axis and enable multiple retrieval of two or more case units from a common retrieval aisle in one common path of the retrieval aisle, ordered / sorted (e.g., according to a predetermined load removal sequence), as described below. For example, still referring to FIG. 1B , one section SECB of storage level 130L includes two storage shelves 1200 and 1210, one shelf having a pitch of Z1A and the other shelf having a pitch of Z1B, where Z1A and Z1B are different from each other. This different pitch allows for the arrangement of case units CUD and CUE having different heights in upper and lower stacks on the common storage level 130L. In other embodiments, pitches Z1A and Z1B may be substantially identical. In this embodiment, storage level 130L includes another storage section SECA having three storage shelves, one shelf having a pitch of Z1E, one shelf having a pitch of Z1D, and another shelf having a pitch of Z1C, where Z1E, Z1D, and Z1C are different from one another. In other embodiments, at least two of pitches Z1E, Z1D, and Z1C are substantially identical. In one embodiment, the pitch between shelves is arranged such that larger and / or heavier case units CUC, CUE are positioned closer to deck 1200S than smaller and / or lighter case units CUD, CUA, CUB. In other embodiments, the pitch between shelves is arranged such that case units are positioned in any suitable location, which may or may not be related to the size and weight of the case units.

[0027] In other embodiments, the vertical pitch between at least some of the rack shelves is the same such that heights Z1A-Z1E between at least some of the shelves are equal, but the vertical pitch between other shelves is different. In still other embodiments, the pitch of rack shelf levels 130LS1-130LS4 on one storage level is a constant pitch (e.g., the rack shelf levels are substantially equally spaced in the Z direction), but the pitch of rack shelf levels 130LS1-130LS4 on different storage levels is a different constant pitch.

[0028] In one embodiment, storage space 130S defined by storage shelf levels 130LS1-130LS4 between storage or deck level 130L accommodates case units of different heights, lengths, widths, and / or weights at different shelf levels 130LS1-130LS4, as described, for example, in U.S. Non-Provisional Patent Application No. 14 / 966,978, filed December 11, 2015, and U.S. Provisional Patent Application No. 62 / 091,162, filed December 12, 2014, the disclosures of which are incorporated herein by reference in their entireties. For example, still referring to FIG. 1B , storage level 130L includes a storage section having at least one intermediate shelf 1210. In the illustrated example, one storage section includes one intermediate shelf 1210, while another storage section includes two intermediate shelves 1210 to form shelf levels 130LS1-130LS4. In one embodiment, the pitch Z1 between storage levels 130L may be any suitable pitch, such as, for example, from about 32 inches to about 34 inches, while in other embodiments, the pitch may be greater than about 34 inches and / or less than about 32 inches. Any suitable number of shelves may be provided between decks 1200S of adjacent vertically stacked storage levels 130L, with the shelves having the same or different pitch between shelves (e.g., see FIG. 1C , where case units CUD1, CUD2, CUE1-CUE3, CUF1, CUF2 are arranged in a vertical stack on one side of the retrieval aisle, and case units CUA, CUB, CUC are arranged in a vertical stack on the opposite side of the retrieval aisle on storage shelves having a substantially similar pitch).

[0029] In one aspect of the disclosed embodiment, the storage or deck level 130L (e.g., the surface along which the bot 110 moves) is arranged at any suitable predetermined pitch Z1, e.g., not an integer multiple of the intermediate shelf pitches Z1A-Z1E. In other aspects, the pitch Z1 may be an integer multiple of the intermediate shelf pitch, e.g., the shelf pitch may be substantially equal to the pitch Z1, such that the corresponding storage space has a height substantially equal to the pitch Z1. As can be appreciated, the shelf pitches Z1A-Z1E are substantially decoupled from the pitch Z1 of the storage level 130L and correspond to the height of a typical case unit, as shown in FIG. 1B. In one aspect of the disclosed embodiment, case units of different heights are dynamically allocated or distributed along each aisle within the storage space 130S with shelf heights commensurate with the height of the case units. The remaining space between storage levels 130L is free for dynamic allocation of cases of corresponding heights along the aisle lengths corresponding to the stored case units (e.g., in the X direction relative to the rack's reference coordinate system REF2, which is the same as the bot's reference coordinate system as it moves down retrieval aisle 130A) and along the stored case units. As can be seen, dynamically allocating case units of different heights onto shelves with different pitches results in layers of stored cases of different heights between storage levels 130L on either side of each retrieval aisle 130A, each case unit being dynamically distributed along the common retrieval aisle 130A such that each case unit within each layer of stored cases is independently accessible (e.g., for retrieval / placement) by bots in the common aisle.Since each aisle length may include multiple case units of different heights and each rack shelf at each shelf level may be filled by dynamic allocation / distribution (e.g., to fill the space of the rack module array RMA in three dimensions in length, width and height to provide a high density storage array), this high density case unit placement / allocation and storage shelf placement results in maximum efficiency of storage space / volume usage between storage levels 130L through optimized case unit SKU distribution, and therefore maximum efficiency of the rack module array RMA.

[0030] 1E and 6A, each of the storage levels 130L includes a single level of storage shelves for storing a single level of case units (e.g., each storage level includes a single case unit support surface CUSP), and the bot 110 is configured to transfer case units to and from the storage shelves of each storage level 130L. For example, the bot 110' shown in FIG. 6A is substantially similar to the bot 110 described herein, except that the bot 110' does not provide sufficient Z-movement of the transfer arm 110PA to place case units on multiple storage shelf levels 130LS1-130LS4 (e.g., accessible from a common rail 1200S) as described above. Here, transfer arm drive 250 (which may be substantially similar to one or more of drives 250A, 250B) includes Z movement sufficient to lift case units off the case unit support surface CUSP of a single level storage shelf for transferring case units to and from loading area 110PL and transferring case units between fingers 273 of transfer arm 110PA and load bed 110PB. Suitable examples of bot 110' may be found, for example, in U.S. patent application Ser. No. 13 / 326,993, filed Dec. 15, 2011, the disclosure of which is incorporated herein by reference in its entirety.

[0031] 2A , in one aspect of the disclosed embodiment, the rack shelves 1210 (including the rack shelves formed by the rails 1200) are longitudinally divided into SECA and SECB (e.g., in the X direction along the length of the pick aisle 130A relative to the storage structure's reference coordinate system RFE2) to form ordered or matched rack shelf sections along each pick aisle 130A. The aisle shelf sections SECA and SECB are ordered / matched relative to each other, for example, based on the pick order of the bots 110 that traverse the aisle on a common path and pick case units specified by a common order fulfillment (e.g., based on an order carryout sequence). In other words, the bot 110 creates a single path (e.g., movement in a single direction) down a single or common pick aisle while picking one or more case units from aisle rack sections SECA, SECB on a common side of pick aisle 130A to build a pick face on the bot 110, the pick face including the case units arranged on the bot according to an order-filling / order-removal sequence as described in further detail below. The aisle rack sections SECA, SECB each include an intermediate shelf in the manner described above. In other embodiments, some of the aisle shelves do not include an intermediate shelf, while others do.

[0032] In one aspect, the ordered aisle rack sections SECA, SECB include different shelf pitches between sections SECA, SECB. For example, aisle rack section SECA has shelves with one or more pitches, while aisle rack section SECB has shelves with one or more different pitches (e.g., different from the shelf pitch of section SECA). According to aspects of the disclosed embodiment, the pitch of at least one intermediate shelf of one aisle rack section SECA, SECB is associated with the pitch of at least one intermediate shelf of another ordered aisle rack section SECA, SECB of the common pick-up aisle 130A. The different pitches of the intermediate shelves 1210 in the ordered aisle rack sections SECA, SECB are selected to be associated and to result in multiple (at least two) ordered picks (i.e., picks in order sequence) by the bot 110 according to an outgoing sequence (e.g., palletizing into a common pallet load) of mixed SKU loads from shelves of different pitches in a common path of the common pick-up aisle 130A. As can be appreciated, the removal of mixed loads from the storage and retrieval system 100 (e.g., for filling truck load ports / pallet loads) is sequenced in a predetermined order according to the various loads exiting the retrieval aisle (e.g., the aisle from which case units are removed for transfer to outgoing pallets), and the shelf pitch of the ordered sections SECA, SECB facilitates the bot 110 to retrieve two or more case units in an ordered sequence according to the order of the load's retrieval sequence in a common retrieval aisle path (e.g., two or more case units are removed in a predetermined order from a common retrieval aisle in one path of the common retrieval aisle).The shelf pitches of the different aisles of the ordered rack sections SECA and SECB are associated to improve the likelihood of ordered multiple picks (pickup of two or more case units from a single aisle with a single path as described above) so that multiple picks are performed by the order processing path of each bot along each aisle, and are associated so that more than half of the cases picked by bots 110 in the storage and pick-up system 100 and intended for a common load removal (e.g., a common pallet load) are picked by the common bot 110 in an ordered order according to the load removal sequence during the single path of the common pick-up aisle (e.g., two or more cases picked by bots 110 are picked from the same pick-up aisle of a single path, e.g., the bots move in a single direction through the pick-up aisle). As can be understood, in one aspect of the disclosed embodiment, both sides PAS1 and PAS2 of the pick-up aisle 130A have ordered aisle rack sections SECA and SECB, and one ordered section may be matched with one or more sections on the same side PAS1 and PAS2 of the common pick-up aisle 130A. As can be appreciated, the rack sections of the matched aisles may be positioned adjacent to one another or spaced apart from one another along the removal aisle 130A.

[0033] 2A, each transfer deck or storage level 130L includes one or more lift pick face interface / transfer stations TS (referred to herein as interface stations TS), where case units or totes (of single or combined case pick faces) are transferred between the lift's load handling device LHD and the bots 110 on the transfer deck 130B. The interface stations TS are located on the opposite side of the transfer deck 130B from the pick aisles 130A and rack modules RM, such that the transfer deck 130B is interposed between the pick aisles and each interface station TS. As mentioned above, each bot 110 on each pick level 130L has access to each storage location 130S, each pick aisle 130A, and each lift 150 on each storage level 130L, and therefore each bot 110 also has access to each interface station TS on the respective level 130L. In one aspect, the interface station TS is offset from the high-speed bot travel path HSTP along the transfer deck 130B so that a bot 110's access to the interface station TS is non-deterministic with respect to the bot's speed on the high-speed travel path HSTP. In this manner, each bot 110 can move a case unit (or pick face, e.g., one or more cases constructed by the bot) from each interface station TS to each storage space 130S according to deck level, and vice versa.

[0034] In one embodiment, the interface station TS is configured for passive transfer (e.g., handover) of case units (and / or pick faces) between the bot 110 and the load handling device LHD of the lift 150 (e.g., the interface station TS does not have moving parts for transporting case units), as described in further detail below. For example, referring also to FIG. 2B , the interface station TS and / or buffer station BS include one or more stacked levels TL1, TL2 of transfer rack shelves RTS, which in one embodiment are similar to the storage shelves described above (e.g., each formed by rails 1210, 1200 and slats 1210S) (e.g., to utilize the lifting capability of the bot 110 relative to the stacked rack shelves RTS), such that handover (e.g., retrieval and placement) of the bot 110 occurs in a passive manner substantially similar to the manner in which case units or totes are transferred to and from the shelves between the bot 110 and the storage space 130S (as described herein). In one embodiment, buffer stations BS on one or more of stacked levels TL1, TL2 also function as handoff / interface stations for the load handling device LHD of lift 150. In one embodiment, when bot 110, such as bot 110′, is configured for the transfer of case units to a single level 130L of storage shelves, interface station TS and / or buffer station BS also include a single level of transfer rack shelves (e.g., substantially similar to the storage rack shelves of storage level 130L described above with respect to FIG. 1D ). As can be appreciated, the operation of a storage and retrieval system including bot 110′ providing a single level of storage and transfer shelves is substantially similar to that described herein.As can also be appreciated, the transfer (e.g., removal and placement) of case units (e.g., individual case units or pick faces) and totes from the load handling devices LHD to and from the stacked rack shelves RTS (and / or single level rack shelves) occurs in a passive manner substantially similar to the manner in which case units or totes are transferred to and from the shelves (as described herein) between the bot 110 and the storage space 130S. In other embodiments, the shelves may include transfer arms (substantially similar to the transfer arm 110PA of the bot 110 shown in FIG. 6, although movement in the Z direction may be omitted if the transfer arm is incorporated into the shelf of the interface station TS) for removing and placing case units or totes from one or more of the load handling devices LHD of the bot 110 and lift 150. Suitable examples of interface stations with active transfer arms are described, for example, in U.S. patent application Ser. No. 12 / 757,354, filed April 9, 2010, the entire disclosure of which is incorporated herein by reference.

[0035] In one embodiment, positioning of the bot 110 relative to the interface station TS occurs in a manner substantially similar to the positioning of the bot relative to the storage space 130S. For example, in one embodiment, positioning of the bot 110 relative to the storage space 130S and the interface station TS occurs in a manner substantially similar to that described in U.S. Patent Application No. 13 / 327,035 (now U.S. Patent No. 9,008,884), filed December 15, 2011, and U.S. Patent Application No. 13 / 608,877 (now U.S. Patent No. 8,954,188), filed September 10, 2012, the disclosures of which are incorporated herein by reference in their entireties. For example, referring to FIGS. 1 and 1D , the bot 110 includes one or more sensors 110S that detect slats 1210S or positioning features 130F (such as openings, reflective surfaces, RFID tags, etc.) disposed on / within the rail 1200. The slats and / or positioning features 130F are arranged to identify the position of the bot 110 within the storage and retrieval system, for example, relative to the storage space and / or interface station TS. In one embodiment, the bot 110 includes a control device 110C that, for example, counts the slats 1210S to at least partially determine the position of the bot 110 within the storage and retrieval system 100. In other embodiments, the positioning features 130F may be arranged to form an absolute or incremental encoder that, when detected by the bot 110, results in a determination of the position of the bot 110 within the storage and retrieval system 100.

[0036] As can be seen, with reference to FIG. 2B , the transfer rack shelves RTS of each interface / transfer station TS define a multiple load station (e.g., having one or more storage case holding positions for holding a corresponding number of case units or totes) on a common transfer rack shelf RS. As described above, each load at the multiple load station is a single case unit / tote or a multiple case pick face (e.g., having multiple case units / totes moved as a unit) that is picked up and placed by either a bot or a load handling device LHD. As can be seen, the above-described bot positioning enables the bot 110 to position itself relative to the multiple load station to pick up and place a case unit / tote and pick face from a given one of the multiple load station's holding positions. The interface / handover station TS defines a multi-position buffer (e.g., a buffer having one or more case holding positions, see FIG. 4B , the buffer being positioned, e.g., along the X-axis of the bot 110 when the bot 110 interacts with the interface station TS) in which incoming and / or outgoing case units / totes and pick faces are temporarily stored as they are transferred between the bot 110 and the load handling device LHD of the lift 150.

[0037] In one embodiment, one or more peripheral buffer / transfer stations BS (substantially similar to the interface stations TS and referred to herein as buffer stations BS) are also disposed on the transfer deck 130B opposite the pick-up aisle 130A and rack modules RM, such that the transfer deck 130B is interposed between the pick-up aisle 130A and each buffer station BS. The peripheral buffer stations BS are interspersed among the interface stations TS or, in one embodiment, are in line with the interface stations TS, as shown in FIGS. 2A and 2B. In one embodiment, the peripheral buffer stations BS are formed by rails 1210, 1200 and slats 1210S and are extensions (albeit separate sections) of the interface stations TS (e.g., the interface stations and the peripheral buffer stations are formed by common rails 1210, 1200). Thus, in one embodiment, the peripheral buffer stations BS include one or more stacked levels TL1, TL2 of transfer rack shelves RTS as described above with respect to the interface stations TS, while in other embodiments, the buffer stations include a single level of transfer rack shelves. The peripheral buffer stations BS define buffers where case units / totes and / or pick faces are temporarily stored while being transferred from one bot 110 to another different bot 110 on the same storage level 130L as described in further detail below. As can be appreciated, in one embodiment, the peripheral buffer stations are located in any suitable location in the storage and retrieval system, including within the retrieval aisle 130A and anywhere along the transfer deck 130B.

[0038] 2A and 2B, in one embodiment, the interface stations TS are arranged along the transfer deck 130B in a manner similar to roadside parking spaces so that the bot 110 "parallel parks" at a given interface station TS to transfer case units to and from one or more shelves RTS at one or more levels TL1, TL2 of the interface station TS. In one embodiment, the transfer orientation of the bot 110 at the interface station TS (e.g., when parallel parked) is the same as the orientation of the bot 110 as it moves along the high-speed bot transport path HSTP (e.g., the interface station is generally parallel to the bot movement direction of the transfer deck and / or the side of the transfer deck on which the lift 150 is positioned). The interaction of the bot 110 with the peripheral buffer station BS also occurs through parallel parking such that the transfer orientation of the bot 110 at the peripheral buffer station BS (e.g., when parallel parked) is the same as the orientation of the bot 110 as it moves along the high-speed bot transport path HSTP.

[0039] 3A and 3B, at least the interface station TS is located on an extension or pier 130BD extending from the transfer deck 130B. In one embodiment, the pier 130BD is similar to a pick-up aisle along which the bot 110 moves along rails 1200S secured to the horizontal support member 1200 (in a manner substantially similar to that described above). In other embodiments, the movement surface of the pier 130BD may be substantially similar to the movement surface of the transfer deck 130B. Each pier 130BD is located on a side of the transfer deck 130B, such as the side opposite the pick-up aisle 130A and the rack module RM, such that the transfer deck 130B is interposed between the pick-up aisle and each pier 130BD. The piers 130BD extend from the transfer deck at a non-zero angle relative to at least a portion of the high-speed bot transport path HSTP. In other embodiments, pier 130BD extends from any suitable portion of transfer deck 130B, including ends 130BE1, 130BE2 of transfer deck 130BD. As can be appreciated, peripheral buffer stations BSD (substantially similar to peripheral buffer stations BS described above) may also be disposed along at least a portion of pier 130BD.

[0040] 4A, 4B, and 5, as described above, in one embodiment, the interface station TS is a passive station, and the load transfer devices LHD of the lifts 150A, 150B have active transfer arms or pick heads 4000A, 4000B. In one embodiment, the inbound lift module 150A and the outbound lift module 150B have different types of pick heads (described below), while in other embodiments, the inbound lift module 150A and the outbound lift module 150B have the same type of pick head, similar to one of the pick heads described below (e.g., both lifts 150A, 150B have pick head 4000A, or both lifts 150A, 150B have pick head 4000B). The pick heads of the lifts 150A, 150B may define, at least in part, the Y-processing axis described herein. In one embodiment, both the inbound and outbound lift modules 150A, 150B have a vertical mast 4002 along which the slide 4001 moves under the motive force of any suitable drive unit 4002D (e.g., connected to the control server 120) configured to raise and lower the slide (and the pick heads 4000A, 4000B mounted thereon). The inbound lift module 150A includes a pick head 4000A mounted to the slide 4001 such that as the slide moves vertically, the pick head 4000A moves vertically with the slide 4001. In this embodiment, the pick head 4000A includes one or more tines or fingers 4273 mounted to a base member 4272. The base member 4272 is movably mounted to one or more rails 4360S of the frame 4200 which are then mounted to the slide 4001. Any suitable drive unit 4005 such as a belt drive, chain drive, screw drive, gear drive, etc. (drive 4005 may be smaller than drive 4002D, and therefore may be substantially similar in form to drive 4002D but not in capacity) is mounted to frame 4200 and coupled to base member 4272 (which has fingers) for driving base member 4272 in the direction of arrow 4050.

[0041] The outbound lift module 150B also includes a pick head 4000B that is attached to the slide 4001 such that the pick head 4000B moves vertically with the slide 4001 as the slide moves vertically. In this embodiment, the pick head 4000B includes one or more pick head portions or effectors (e.g., transfer arms) LHDA, LHDB, each having one or more tines or fingers 4273 attached to a respective base member 4272A. Each base member 4272A is movably attached to one or more rails 4360SA of a frame 4200A that is in turn attached to the slide 4001. Any suitable drive unit 4005A, such as a belt drive, chain drive, screw drive, gear drive, etc., is mounted to the frame 4200A and coupled to each base member 4272A (which includes fingers) for driving the respective base member 4272A in the direction of arrow 4050 (each effector has its own drive unit such that each effector is independently movable in the direction of arrow 4050). Although two effectors LHDA, LHDB are shown on the pick head 4000B, the pick head 4000B may include any suitable number of effectors corresponding, for example, to the number of case unit / pick face holding positions of the interface station TS, such that case units / pick faces are individually picked from the interface station TS as described in further detail below.

[0042] As can be appreciated, lift modules 150A, 150B are under the control of any suitable controller, such as control server 120, such that when retrieving and placing case units, the pick heads are raised and / or lowered to a predetermined height corresponding to an interface station TS of a predetermined storage level 130L. As can be appreciated, lift modules 150A, 150B provide a Z-handling axis (relative to both the bot reference frame REF and the rack reference frame REF2) of the storage and retrieval system, where output lift module 150B sorts case units on the fly for transport to output station 160US, as described below. At interface station TS, pick heads 4000A, 4000B, or individual portions thereof (e.g., effectors LHDA, LHDB), are extended to engage fingers 4273 between slats 1210S (shown in FIG. 4B ) below the case units being retrieved, corresponding to one or more case unit holding positions of interface station TS from which one or more case units are retrieved. The lifts 150A, 150B raise the pick heads 4000A, 4000B to lift the case units from the slats 1210S and retract the pick heads 4000A, 4000B for transporting the case units to another level of the storage and retrieval system, such as to transport the case units to the unloading station 160UT. Similarly, to place one or more case units, the pick heads 4000A, 4000B or individual parts thereof (e.g., effectors LHDA, LHDB) are extended so that the fingers 4273 are above the slats corresponding to one or more case unit holding positions of the interface station TS where the one or more case units are being placed. The lifts 150A, 150B lower the pick heads 4000A, 4000B to place the case units on the slats 1210S and so that the fingers 4273 are engaged between the slats 1210S below the case units being removed.

[0043] Referring now to FIG. 6 , as described above, the bot 110 includes a transfer arm 110PA that effects the removal and placement of case units from stacked storage spaces 130S (defined at least in the Z direction), interface stations TS, and peripheral buffer stations BS, BSD (e.g., the storage spaces, interface stations, and / or peripheral buffer stations may be further defined in the X and Y directions relative to either the rack reference frame REF2 or the bot reference frame REF through dynamic case unit allocation as described above) via one or more of rails 1210A-1210C, 1200. As can be appreciated, the bot defines an X-handling axis and, as further described below, at least in part a Y-handling axis (e.g., relative to the bot reference frame REF). The bot 110 transports case units between each lift module 150 on a respective storage level 130L and each storage space 130S, as described above. The bot 110 includes a frame 110F having a drive section 110DR and a loading section 110PL. The drive section 110DR includes one or more drive wheel motors, each connected to a respective drive wheel 202, for propelling the bot 110 along the X direction (relative to the bot reference frame REF to define the X processing axis). As can be appreciated, the X axis of bot movement coincides with the storage position of the bot 110 as it moves through the retrieval aisle 130A. In this embodiment, the bot 110 includes two drive wheels 202 positioned on either side of the bot 110 at end 110E1 (e.g., first longitudinal end) of the bot 110 to support the bot 110 on a suitable drive surface, although in other embodiments, any suitable number of drive wheels are provided on the bot 110. In one embodiment, each drive wheel 202 is independently controlled so that the bot 110 can be steered through differential rotation of the drive wheels 202, although in other embodiments, the rotation of the drive wheels 202 may be coupled to rotate at substantially the same speed.To support the bot 110 on the drive surface, any suitable wheels 201 are attached to the frame on either side of the bot 110 at the end 110E2 (e.g., the second longitudinal end) of the bot 110. In one embodiment, the wheels 201 are freely rotating caster wheels, which allow the bot 110 to pivot through differential rotation of the drive wheels 202 to change the direction of movement of the bot 110. In other embodiments, the wheels 201 are steerable wheels that turn, for example, under the control of a bot control device 110C (configured to provide control of the bot 110 as described herein), to change the direction of movement of the bot 110. In one embodiment, the bot 110 includes one or more guide wheels 110GW, for example, at one or more corners of the frame 110F. The guide wheel 110GW may interact with the storage structure 130, such as a guide rail (not shown) in the retrieval aisle 130A, on the transfer deck 130B and / or at an interface or transfer station to interact with the lift module 150 to guide and / or position the bot 110 a predetermined distance to where one or more case units are to be placed and / or from where one or more case units are to be removed, as described, for example, in U.S. Patent Application No. 13 / 326,423, filed December 15, 2011, the entire disclosure of which is incorporated herein by reference. As described above, the bot 110 may enter the retrieval aisle 130A having different opposing directions to access storage spaces 130S located on both sides of the retrieval aisle 130A. For example, the bot 110 may enter the retrieval aisle 130A with the end 110E2 leading the direction of movement, or the bot 110 may enter the retrieval aisle 130A with the end 110E1 leading the direction of movement.

[0044] The loading section 110PL of the bot 110 includes a loading bed 110PB, a fence or reference member 110PF, a transfer arm 110PA, and a pusher bar or member 110PR. In one embodiment, the loading bed 110PB includes one or more rollers 110RL laterally attached to the frame 110F (e.g., relative to the longitudinal axis LX of the bot 110) so that one or more case units carried within the loading section 110PL can be moved longitudinally along the longitudinal axis of the bot (e.g., to justify with respect to a predetermined position of the frame / loading section and / or positional references of one or more case units), for example, to position the case unit in a predetermined position within the loading section 110PL and / or with respect to other case units within the loading section 110PL (e.g., longitudinal forward / rearward alignment of the case unit). In one embodiment, rollers 110RL may be driven (e.g., rotated about their respective axes) by any suitable motor to move case units within loading section 110PL. In another embodiment, bot 110 includes one or more longitudinally movable pusher bars (not shown) that push case units past rollers 110RL to move the case units to a predetermined position within loading section 110PL. The longitudinally movable pusher bars may be substantially similar to those described, for example, in U.S. Patent Application No. 13 / 326,952, filed December 15, 2011, the entire disclosure of which has been incorporated herein by reference. The pusher bar 110PR is movable in the Y direction relative to the reference coordinate system REF of the bot 110 to effect lateral alignment of the case units within the loading area 110PL along the fence 110PF and / or the pick-up head 270 of the transfer arm 110PA in a manner described in U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, the entire disclosure of which is already incorporated by reference herein.

[0045] Still referring to FIG. 6 , case units are placed on and removed from the load bed 110PB by the transfer arm 110PA along the Y processing axis. The transfer arm 110PA includes a lift mechanism or unit 200 located within the load section 110PL substantially as described, for example, in U.S. Provisional Patent Application No. 62 / 107,135, filed January 23, 2015, the entire disclosure of which is already incorporated herein by reference. The lift mechanism 200 provides both coarse and fine positioning of pick faces grasped by the bot 110, which are vertically lifted into position in the storage structure 130 for retrieval and / or placement of the pick faces and / or individual case units into storage spaces 130S (e.g., on the respective storage level 130L where the bot 110 is located). For example, the lift mechanism 200 provides for the removal and placement of case units at a plurality of elevated storage shelf levels 130LS1-130LS4, TL1, TL2 accessible from a common removal aisle or interface station deck 1200S (see, e.g., Figures 1B, 2B, and 3B).

[0046] The lift mechanism 200 is configured to perform combined robot axis movements (e.g., combined, substantially simultaneous movements of the pusher bar 110PR, the lift mechanism 200, the pick head extension, and a front / rear alignment mechanism, such as the longitudinally movable pusher bar described above) to allow different / multiple SKUs or multiple pick loads to be handled by the robot. In one embodiment, the operation of the lift mechanism 200 is independent of the operation of the pusher bar 110PR, as described below. Decoupling the axes of the lift mechanism 200 and the pusher bar 110PR results in a combined pick / place sequence, which can reduce pick / place cycle times, increase throughput of the storage and pick system, and / or increase storage density of the storage and pick system, as described above. For example, the lift mechanism 200 can provide pick and place of case units at multiple elevated storage shelf levels accessible from a common pick aisle and / or interface station deck 1200S, as described above.

[0047] The lift mechanism may be configured in any suitable manner to allow the pick-up head 270 of the robot 110 to move bidirectionally along the Z axis (e.g., reciprocate in the Z direction, see FIG. 6 ). In one embodiment, the lift mechanism includes a mast 200M, and the pick-up head 270 is movably mounted to the mast 200M in any suitable manner. The mast is movably mounted to the frame in any suitable manner to allow movement along the robot 110's lateral axis LT (e.g., in the Y direction to define a Y processing axis). In one embodiment, the frame includes guide rails 210A, 210B to which the mast 200 is slidably mounted. Transfer arm drives 250A, 250B may be attached to the frame to effect movement of the transfer arm 110PA along at least the lateral axis LT (e.g., the Y axis) and the Z axis. In one embodiment, the transfer arm drives 250A, 250B include an extension motor 301 and a lift motor 302. The extension motor 301 may be mounted to the frame 110F and may be coupled to the mast 200M in any suitable manner, such as by a belt and pulley transmission 260A, a screw drive transmission (not shown), and / or a gear drive transmission (not shown). The lift motor 302 may be mounted to the mast 200M and may be coupled to the pick head 270 in any suitable manner, such as by a belt and pulley transmission 271, a screw drive transmission (not shown), and / or a gear drive transmission (not shown). As an example, the mast 200M includes guides, such as guide rails 280A, 280B, and the pick head 270 is mounted along the guide rails 280A, 280B for guided movement in the Z direction along the guide rails 280A, 280B. In other embodiments, the pick head is mounted to the mast in any suitable manner for guided movement in the Z direction. With respect to transmission unit 271, belt 271B of belt and pulley transmission unit 271 is fixedly coupled to removal head 270 so that when belt 271 moves (e.g., driven by motor 302), removal head 270 moves with belt 271 and is driven in both directions in the Z direction along guide rails 280A, 280B.As can be appreciated, if a screw drive is used to drive the pick head 270 in the Z direction, a nut may be attached to the pick head 270 such that engagement between the nut and the screw causes movement of the pick head 270 when the screw is turned by the motor 302. Similarly, if a gear drive transmission is used, a rack and pinion or any other suitable gear drive may drive the pick head 270 in the Z direction. In other embodiments, any suitable linear actuator is used to move the pick head in the Z direction. The transmission 260A for the extension motor 301 is substantially similar to that described herein with respect to transmission 271.

[0048] Still referring to FIG. 6, the pick head 270 of the bot 110 transfers case units between the bot 110 and a case unit pick / placement location, such as, for example, the storage space 130S, the peripheral buffer stations BS, BSD, and / or the interface station TS (see FIGS. 2A-3B), or in other embodiments, directly between the bot 110 and the lift module 150. In one embodiment, the pick head 270 includes a base member 272, one or more tines or fingers 273A-273E, and one or more actuators 274A, 274B. The base member 272 is attached to the mast 200M as described above so as to ride along the guide rails 280A, 280B. One or more tines 273A-273E are attached to base member 272 at their proximal ends such that their distal (e.g., free) ends are cantilevered from base member 272. Referring again to FIG. 1D , tines 273A-273E are configured for insertion between slats 1210S that form the case unit support surface CUSP of the storage shelf.

[0049] One or more of the tines 273A-273E are movably mounted to the base member 272 (such as on slide / guide rails similar to those described above) so as to be movable in the Z direction. In one embodiment, any number of tines may be mounted to the base member 272, but in the embodiment shown in the drawings, for example, five tines 273A-273E are mounted to the base member 272. Any number of the tines 273A-273E may be movably mounted to the base member 272, but in the embodiment shown in the drawings, for example, only the outermost tines 273A, 273E (relative to the centerline CL of the pick head 270) are movably mounted to the base member 272, while the remaining tines 273B-273D are immovable relative to the base member 272.

[0050] In this embodiment, pick head 270 uses only three tines 273B-273D to transfer smaller-sized case units (and / or groups of case units) to and from bot 110, and five tines 273A-273E to transfer larger-sized case units (and / or groups of case units) to and from bot 110. In other embodiments, fewer than three tines are used to transfer smaller-sized case units (e.g., when three or more tines are movably attached to base member 272). For example, in one embodiment, all but one of tines 273A-273E are movably attached to base member 272 so that the smallest case unit being transferred to and from bot 110 has a width equivalent to the distance X1 between slats 1210S, e.g., without interfering with other case units on a storage shelf (see FIG. 1D).

[0051] The non-movable tines 373B-373D define the pick surface SP of the pick head 270 and are used when transferring case units (and / or pick faces) of all sizes, while the movable tines 373A, 373E are selectively raised and lowered (e.g., in the Z direction by actuators 274A, 274B) relative to the non-movable tines 373B-373D to transfer larger case units (and / or pick faces). Still referring to Figure 6, an example is shown in which all of the tines 273A-273E are positioned so that the case unit support surface SF of each tine 273A-273E coincides with the removal surface SP of the removal head 270, but as can be understood, the case unit support surfaces SF of the tines 273A, 273E are offset (e.g., downward) from the removal surface SP, and the two end tines 273A, 273E are movable to be positioned lower (e.g., in the Z direction) relative to the other tines 273B-273D so that the tines 273A, 273E do not come into contact with one or more case units grasped by the removal head 270 and do not interfere with unremoved case units positioned in storage space 130S or any other suitable case unit holding position on the storage shelf.

[0052] Movement of the tines 273A-273E in the Z direction is effected by one or more actuators 274A, 274B mounted in any suitable location on the transfer arm 110PA. In one embodiment, the one or more actuators 274A, 274B are mounted to the base member 272 of the pick head 270. The one or more actuators are any suitable actuators, such as linear actuators, capable of moving one or more tines 273A-273E in the Z direction. For example, in the embodiment shown in FIG. 6, there is one actuator 274A, 274B for each of the movable tines 273A, 273E such that each movable tine is independently movable in the Z direction. In other embodiments, one actuator may be coupled to two or more movable tines such that the two or more movable tines move together in the Z direction.

[0053] As can be appreciated, movably mounting one or more tines 273A-273E on the base member 272 of the pick head 270 provides full support for larger case units and / or pick faces on the pick head 270 while also providing the ability to pick and place smaller case units without interfering with other case units located on, for example, the storage shelves, interface stations, and / or peripheral buffer stations. The ability to pick and place case units of various sizes without interfering with other case units on the storage shelves, interface stations, and / or peripheral buffer stations reduces the size of the gap GP (see FIG. 1B) between case units on the storage shelves. As can be appreciated, because the tines 273B-273D are fixed to the base member 272, the raising and lowering of case units and / or pick faces to and from the case unit holding positions is effected solely by the lift motors 301, 301A, so there is no overlapping motion when picking / placing case units.

[0054] Referring again to FIG. 6 , it is also noted that the pusher bar 110PR is movable independently of the transfer arm 110PA. The pusher bar 110PR is movably mounted to the frame in any suitable manner, such as, for example, a guide rod and slide arrangement, and is actuated along the Y direction (e.g., a direction generally parallel to the extension / retraction direction of the transfer arm 110PA). In one embodiment, at least one guide rod 360 is mounted within the loading section 110PL to extend transversely relative to the longitudinal axis LX of the frame 110F. The pusher bar 110PR may include at least one slide member 360S configured to engage and slide along a respective guide rod 360. In one embodiment, at least the guide rod / slide arrangement is coupled within the loading section 110PL to retain the pusher bar 110PR. The pusher bar 110PR is actuated by any suitable motor and transmission, such as motor 303 and transmission 303T. In one embodiment, motor 303 is a rotary motor and transmission 303T is a belt and pulley transmission. In other embodiments, pusher bar 110PR may be actuated by a linear actuator having substantially no rotating parts.

[0055] The pusher bar 110PR is positioned within the loading section 110PL so as to be substantially perpendicular to the rollers 110RL and not interfere with the pick-up head 270. As can be seen in FIG. 10B, the bot 110 is in a transport configuration in which at least one case unit is supported on the rollers 110RL (e.g., the rollers collectively form a loading bed). In the transport configuration, the tines 273A-273E of the pick-up head 270 are intermeshed with the rollers 110RL and positioned below (along the Z direction) the case unit support surface RSP (see FIG. 10) of the rollers 110RL. The pusher bar 110PR is configured with grooves 351 (FIG. 10C) into which the tines 273A-273E fit, with sufficient clearance provided within the grooves 351 to allow the tines to move below the case unit support surface RSP and to allow free movement of the pusher bar 110PR without interference from the tines 273A-273E. The pusher bar 110PR also includes one or more openings through which the rollers 110RL pass, the openings being sized to allow free rotation of the rollers about their respective axes. As can be appreciated, the independently operable pusher bar 110PR does not interfere with the lateral (e.g., Y-direction) extension of the rollers 110RL, the transfer arm 110PA, and the raising / lowering of the take-out head 270.

[0056] As described above, because the pusher bar 110PR is a separate, independent axis of the robot 110 that operates without interference from the extension and lift axes of the pick head 270, the pusher bar 110PR can be operated substantially simultaneously with the lifting and / or extension of the transfer arm 110PA. Combined axis movement (e.g., simultaneous movement of the pusher bar 110PR with the extension and / or lift axes of the transfer arm 110PA) can result in increased load operation throughput along the Y processing axis, resulting in ordered multiple picking (e.g., according to a predetermined load removal sequence) of two or more case units from a common pick-up aisle in one common path of the pick-up aisle. 10-10A, during a multiple pick / place sequence of the transfer arm 110PA, the pusher bar 110PR is pre-positioned (as the case units and / or pick faces are picked and transferred into the loading section 110PL) a predetermined distance X2 away from the contact depth X3 (e.g., the depth of the tines occupied by the case units and / or pick faces CU when being picked / placed from a storage space or other case unit holding location) (FIG. 14, block 1100). Distance X2 is the minimum distance that provides sufficient clearance between the pusher bar 110PR and the case units to allow the case units to seat on the rollers 110RL. When the case unit CU is lowered onto the rollers 110RL (FIG. 14, block 1110), the distance the pusher bar 110PR travels to contact the case unit CU is a shorter distance X2 compared to the distance X4 traveled by a conventional transport vehicle when moving from the rear 402 of the loading section 110PL (relative to the lateral and access side 401 of the loading section 110PL). Once the case unit CU is lowered by the transfer arm 110PA and transferred to the rollers 110RL so as to be supported only by the rollers 110RL, the pusher bar 110PR is actuated forward (relative to the lateral and access side 401 of the loading section 110PL) to align the case unit CU (FIG. 14, block 1120).For example, the pusher bar 110PR may push the case unit CU laterally in the Y direction so that the case unit contacts the fence 110PF (positioned on the access side 401 of the loading section 110PL so that a reference position for the case unit can be formed through contact between the case unit CU and the fence 110PF). In one embodiment, the pusher bar 110PR may engage or grip the case unit CU during transport (e.g., to hold the case unit relative to the fence 110PF) to maintain the case units CU in a predetermined spatial relationship relative to each other and to the reference coordinate system REF ( FIG. 6 ) of the robot 110 ( FIG. 14 , block 1130). Upon positioning the case unit, the pusher bar 110PR is withdrawn from contact with the case unit CU (e.g., in the Y direction) after aligning the case unit CU with the fence 110PF ( FIG. 14 , block 1140). Substantially immediately after the pusher bar 110PR disengages from the case unit CU, one or more of the lift axis (e.g., in the Z direction) and extension axis (e.g., in the Y direction) of the transfer arm 110PA are actuated substantially simultaneously with the withdrawal of the pusher bar 110PR ( FIG. 14 , block 1150). In one embodiment, both the lift axis and the extension axis are actuated as the pusher bar is withdrawn from contact with the case unit CU, while in other embodiments, only one of the lift axis and the extension axis is actuated. As can be appreciated, the simultaneous actuation of the lift axis and / or extension axis of the transfer arm 110PA with the withdrawal of the pusher bar 110PR, and the reduction in the distance the pusher travels to align the case unit CU, reduces the time required to transfer case units CU to and from the bot 110, increasing the throughput of the storage and retrieval system 100.

[0057] 2A, 2B, and 12, each bot 110 is configured to transport pick faces between the pick-up aisle 130A and the transfer / handover station TS and buffer station BS. In one embodiment, the control server 120 is configured to instruct the bots 110 to effect the classification of the order of cases in the outflow (also referred to as the order processing stream, outflow stream, or order processing) by the bots 110 independent of the order in which the bots 110 that form the pick face retrieve cases from the storage area. In one embodiment, the bot control device 110C is configured to instruct the bots 110 to effect the classification of the order of cases in the outflow (also referred to as the order in which the bots 110 that form the pick face retrieve cases from the storage area. In yet another aspect, both the control server 120 and the bot controller 110C are configured to instruct the bots 110 to effect a classification of the order of cases in the outgoing flow by the bots 110 independent of the order in which cases are removed from the storage area by the bots 110 forming the pick face. Thus, the control server 120 and / or the bot controller 110C are configured to set the flow of outgoing cases, at least in part, in conjunction with the bots 110's classification of cases commonly carried by the bots 110, independent of the order in which cases are removed from the storage area by the bots 110.As can be appreciated, in one embodiment, each bot 100 is configured to transport pick faces between a first pick face interface station (e.g., a transfer / handover station TS and / or buffer station BS) and a second pick face interface station (e.g., a transfer / handover station TS and / or buffer station BS spaced apart from the first pick face interface station), and as described herein, the bot 110 retrieves the first pick face from the first interface station, travels across the transfer deck 130B, and places / buffers the first pick face or at least a portion thereof at the second pick face interface position so that the second pick face interface station has multiple pick faces buffered on a common support / surface CS in a sequence of pick faces ordered according to a predetermined case ejection order sequence for mixed case pick faces. As described below, the bot 110 is configured to transfer a first pick face PCF1 having any suitable number of case units therein from the pick-up aisle 130A (or transfer station TS or buffer station BS) and place a second pick face PCF2, different from the first pick face PCF1, onto a common surface CS (such as a rack shelf RTS) of the transfer / handover station TS (or buffer station BS) common to the bot 110 and the lift 150B. For purposes of explanation, this may also be referred to as a classification of the outbound flow by the bots of the transfer station (and / or buffer station). Also, as described below, the first and second pick faces, in one aspect, have at least one case unit common to both the first and second pick faces.In one aspect, as described herein, the bot 110 is configured to construct a first pick face (e.g., at least one of a plurality of pick faces) on the fly, for example, during a traverse from a first pick position in the pick path 130A to the placement of a second pick face at the transfer / handover station TS (or buffer station BS) in a multiple pick / place sequence (e.g., while the bot is moving). In another aspect, the bot 110 is configured to construct a first pick face (e.g., at least one of a plurality of pick faces to be placed on a common surface CS) on the fly, for example, during a traverse from a first pick position to the transfer / handover station TS (or buffer station BS) in a multiple pick / place sequence (e.g., while the bot is stationary at the second pick face interface station or the buffer of the second pick face interface station). As can be appreciated, when a pick face is removed from a first pick face interface station, such as a transfer station TS or a buffer station BS, by, for example, the bot 110, and placed in a second pick face interface station, such as another transfer station TS or a buffer station BS, the pick face bypasses storage (e.g., is not placed in storage space 130S before transport to the second pick face interface station). In other embodiments, at least a portion of the pick face removed from the first pick face interface station is placed in storage space 130S (e.g., of a storage rack array RMA) by the bot 110 before transport to the second pick face interface station.In one embodiment, the pick face removed from the inbound transfer station TS (or buffer station BS) may be the same pick face placed at the outbound transfer station TS (or buffer station BS) (i.e., the pick face is not broken up during transport from the inbound transfer station TS / buffer station BS to the outbound transfer station TS / buffer station BS, and the transport between the inbound and outbound stations may or may not include the placement of the pick face in storage).

[0058] The control device 110C of the bot 110 is configured to cause on-the-fly construction of the first pick face (or any other pick face picked by the bot 110). In one embodiment, the bot 110 is configured to load the bot 110 and build the pick face, for example, in the loading section 110PL, as described herein, and the case units / pick faces are picked up by the bot and placed in the loading section in a predetermined order or sequence. In one embodiment, the bot 110 is configured to pick / build a pick face PCF3 different from the first pick face PCF1 and place this different pick face PCF3 on a shelf (such as another rack shelf RTS stacked above or below the rack shelf forming a common surface CS) of the transfer / handover station TS (or buffer station BS). The bot 110 includes case manipulation as described herein. The lift 150B is configured to retrieve a first pick face PCF1, further retrieve a second pick face PCF2 (forming a different pick face PCF3) from one or more case units on the rack shelf RTS (or other location, such as a storage shelf in a pick aisle), and place this different pick face PCF3 on the common surface CS. As can be appreciated, in one embodiment, the lift 150B is configured to retrieve a second pick face PCF2 from the transfer / transfer station TS. In another embodiment, the lift 150B is configured to retrieve a third pick face PCF4 from the common surface CS (such as the rack transfer shelf RTS) of the transfer / transfer station TS (or buffer station BS), as described herein, where the third pick face PCF4 is different from the first and second pick faces PCF1, PCF2, and a common case is common to the first, second, and third pick faces PCF1, PCF2, PCF4. As can be seen, a second interface station (such as transfer station TS or buffer station BS) forms a common pick face transfer interface with lift 150 so that commonly supported pick faces are commonly retrieved by lift 150.It is noted that the ability of the lift 150 to retrieve individual pick faces from different deck levels, as described above, results in sorting of the pick faces in the Z process axis.

[0059] In one aspect of the disclosed embodiment, as can be appreciated, in a multiple pick / place sequence, multiple case units are transported and manipulated substantially simultaneously within the loading section 110PL (e.g., to form one or more pick faces) to further increase the throughput of the storage and pick-up system 100 and to effect multiple pick / place sequences according to a predetermined order delivery sequence. Referring again to FIG. 1 , the bots receive pick and place instructions, for example, from the control server 120 (and / or the warehouse management system 2500), and the bot controller 110C executes these instructions to form the ordered multiple picks. Here, the bots 110 enter the common aisle 130A1, for example, from the transfer deck 130B, to form a single or common path through the pick aisle 130A1, during which the bots 110 pick two or more case units according to a predetermined order delivery sequence ( FIG. 15 , block 1201A). In one aspect, the operation of the case unit CU is the classification of the case unit (in other words, the removal and placement of the case unit according to a predetermined load removal sequence), where the case is placed on the transfer arm 110PA for removal / placement of the case unit or is positioned so that the case unit is not transferred to or remains on the transfer arm 110PA while other case units are transferred to and from the transfer arm 110PA. Here, the bot 110 moves through the common removal aisle 130A1 in the direction of arrow XC and stops at a predetermined storage space 130S1 according to a predetermined order removal sequence, where the bot 110 removes one or more case units from the predetermined storage space 130S1 by the common transfer arm 110PA, and the placement of the case units on the common transfer arm 110PA corresponds to the predetermined order removal sequence described in further detail below (e.g., the case units are classified on the fly, e.g., during transport by the bot 110).

[0060] 10B-10E, as an example of case operations on the bot 110, a case unit CUA is removed from a case unit holding location (e.g., from a storage space 130S in a common pick-up aisle to effect ordered multiple pick-ups, or in other embodiments, from a lift interface station TS and / or a case unit buffer station BS located on a pick-up aisle or transfer deck) and transferred into the loading section 110PL (FIG. 15, block 1201B). Once the case unit CUA is transferred into the loading section 110PL, the pusher bar 110PR may be pre-positioned adjacent to the fence 110PF (FIG. 15, block 1204) so ​​that the pusher bar 110PR is positioned between the case unit CUA and the fence 110PF when the case unit CUA is lowered for transfer to the rollers 110RL (FIG. 15, block 1205). The pusher bar 110PR is actuated to push the case unit CUA (which is resting on the roller 110RL) in the Y direction toward the rear (e.g., rear) 402 of the loading section 110PL so that the case unit CUA contacts the alignment surfaces 273JS (FIG. 10) of the tines 273A-273E and is aligned with the rear 402 of the loading section 110PL (FIG. 15, block 1210).

[0061] In one aspect, the bot 110 continues to travel in the same direction XC through the common pick-up aisle 130A1 (e.g., so that all case units in an ordered multiple pick-up are picked up along a common path in the pick-up aisle by the bot 100 moving in a single direction) and stops at another predetermined storage space 130S according to a predetermined order ejection sequence. As described above, the pusher bar 110PR remains in contact with (grasps) the case unit CUA during the transport of the case unit between case unit holding positions so that the case unit CUA remains in a predetermined position (and / or in a predetermined longitudinal position) at the rear 402 of the loading section 110PL relative to the reference coordinate system REF of the bot 110 (FIG. 15, block 1215). For example, to retrieve a subsequent case unit from another storage space 130S2 in the common retrieval aisle 130A1, the pusher bar 110PR is moved in the Y direction to disengage the case unit CUA, and the lift and extension axes of the transfer arm 110PA are actuated to retrieve another case unit CUB from the other storage space 130S2 (or in other embodiments, for example, from the lift / transfer interface station TS and / or buffer / transfer station BS as described above) ( FIG. 15 , block 1220). While the case unit CUB is being retrieved, the pusher bar 110PR is positioned adjacent to the rear 402 of the loading section 110PL in the Y direction so as to be located between the case unit CUA and the alignment surfaces 273JS of the tines 273A-273E ( FIG. 15 , block 1225). The case unit CUB is transferred into the loading section and lowered / placed onto the rollers 110RL so that the case units CUA, CUB are positioned relative to each other along the Y axis (FIG. 15, block 1230). The pusher bar 110PR is actuated in the Y direction to push the case units CUA, CUB towards the fence 110PF to align the case units CUA, CUB forward (FIG. 15, block 1234) and grip / hold the case units CUA, CUB for transport (FIG. 15, block 1235).As can be appreciated, in one embodiment, case units CUA, CUB are positioned together at the case unit holding location, while in other embodiments, case units CUA, CUB are sorted and, for example, transported and positioned at separate locations in the common case unit holding location, or are positioned at different case unit holding locations, as described in further detail below (FIG. 15, block 1240). For example, and referring also to FIGS. 7-9, bot 110 carrying the ordered multiple pick-up load transfers the ordered multiple pick-up case units to one or more interface stations TS (including buffer shelves 7000A-7000L) corresponding to output lifts 150B1, 150B2.

[0062] As can be appreciated, in one embodiment in which a bot 110 "parallel parks" into interface station TS (FIG. 7) or turns into pier 130BD (FIG. 8), the spacing between bots traveling on the high-speed bot transport path HSTP of transfer deck 130B (FIG. 2A) is such that a bot interacting with interface station TS can slow down and turn into interface station TS substantially without interference from and / or with another bot 110 traveling along transfer deck 130B. In other embodiments, because transfer deck 130B is substantially open and configured for non-deterministic movement of bots 110 across and along transfer deck 130B as described above, bots traveling on the transfer deck may maneuver around bots turning into interface stations. When multiple pick-up case units are placed in different positions on a common buffer shelf 7000A-7000L of the interface / transfer station of lifts 150B1, 150B2, for example, bot 110 places a first CUB of the case unit (for illustrative purposes, corresponding to pick face 7 in FIG. 9 and including a single case unit in this example) in a first position on buffer shelf 7000B and places a second CUA of the case unit (for illustrative purposes, corresponding to pick face 5 in FIG. 9 and including a single case unit in this example) in a second position on buffer shelf 7000B. When multiple pick-up case units are placed in a common case unit holding position, bot 110 places both case units CUA and CUB as a single unit (e.g., pick faces) in a common position on buffer shelf 7000A, for example (for illustrative purposes, corresponding to pick face 9 in FIG. 9 and including two case units in this example).

[0063] When the case units CUA and CUB are sorted for placement at a separate location from the common case unit holding position or at another case unit holding position (FIG. 15, block 1250), the case units CUA and CUB are separated from each other in the loading section 110PL. For example, the pick-up head 270 of the transfer arm 110PA can be moved in the Z direction to lift the case units CUA and CUB from the rollers 110RL by an amount sufficient to allow the pusher bar 110PR to pass directly underneath the case units (FIG. 16, block 1250A). Once the case units CUA and CUB are lifted, the pusher bar 110PR is positioned along the Y direction between the case units CUA and CUB (see FIG. 10E) (FIG. 16, block 1250B). The pick-up head 270 is lowered so that the case units CUA and CUB are transferred to the rollers 110RL and the pusher bar is inserted between the case units CUA and CUB (FIG. 16, block 1250C). The pusher bar 110PR is moved in the Y direction to move the case unit CUA toward the rear 402 of the loading section 110PL (e.g., relative to the alignment surfaces 273JS of the tines 273A-273E, or any other suitable position) (e.g., to separate the case units), while the case unit CUB remains in front of the loading section 110PL adjacent the fence 110PF (e.g., as shown in FIG. 10C ) ( FIG. 16 , block 1250D). As can be appreciated, when a case unit is held against the alignment surfaces 273JS of the tines during transport, the pusher bar is moved in the Y direction to move the case unit CUB toward the front 401 of the loading section 110PL (e.g., relative to the fence 110PF, or any other suitable position) (e.g., to separate the case units), while the case unit CUA remains in the rear of the loading section 110PL adjacent the alignment surfaces 273JS.The pusher bar 110PR may be moved in the Y direction to realign the case unit CUB with the fence 110PF to place the case unit on the tines 273A-273E for placement at the case unit holding position (FIG. 16, block 1250E). As can be seen, with the case unit CUA positioned substantially against the alignment surfaces 273JS of the tines 273A-273E (e.g., of the pick head 270), the case unit CUB can be placed at the case unit holding position substantially without interference from the case unit CUA (FIG. 16, block 1250F), e.g., the case unit CUA avoids contact with the case unit placed at the case unit holding position. The case unit CUA is lowered / transferred back into the loading section 110PL (e.g., by retracting and lowering the transfer arm 110PA) (FIG. 16, block 1250G). The pusher bar 110PR, which has been previously positioned between the alignment surface 273JS and the case unit CUA, pushes the case unit CUA, which is positioned on the roller 110RL, against the fence 110PF to align the case unit CUA forward for placement at another case unit holding position (e.g., different from the holding position where the case unit CUB is positioned) (FIG. 16, block 1250H). The pusher bar 110PR remains opposed to the case unit CUA to grip the case unit (e.g., by the fence) during transport to the other case unit holding position (FIG. 16, block 1250I). The pusher bar 110PR moves away from the case unit CUA, and the transfer arm is actuated to raise and extend the pick head 270 to place the case unit CUA at the other case unit holding position (FIG. 16, block 1250J).

[0064] An example of a case unit transfer process for a bot 110, including multiple pick and place operations of case units with on-the-fly sorting of case units to create a mixed pallet load MPL (shown in FIG. 1F) and / or to process a predetermined order sequence of items picked at an operator station or cell 160EP according to a predetermined order output sequence in one or more bags, totes, or other containers TOT (e.g., as shown in FIG. 26 to process a customer order), is described with respect to FIGS. 9 and 11-13 in accordance with aspects of the disclosed embodiment. For example, with reference to FIG. 11, a customer order may request that case unit 7 be delivered to output lift 150B1 and that case unit 5 also be delivered to output lift 150B1. (Note that in other aspects, a customer order may request that case units delivered by a common bot 110 be delivered to different output lifts 150B1, 150B2 (FIG. 9), such that the transfer of case units delivered by a common bot 110 to different output lifts occurs in a manner substantially similar to that described herein.) In aspects of the disclosed embodiments described herein, the output lift 150B1 (e.g., output lifts 150B1, 150B2, respectively, of a storage and retrieval system / order fulfillment system) defines a mixed case pick face processing path or aisle (also referred to as a stream) in which mixed case pick faces are output from the storage array to a load fill section where they enter and exit the processing path in substantially the same order. As can be appreciated, while the input and output lifts 150A, 150B are described as vertically reciprocating lifts, it should be understood that in other aspects the input and output lifts 150A, 150B are any suitable transport modules for transporting case pick faces to and from the storage structure 130 (e.g., between respective pick face interface stations, such as transfer station TS or buffer station BS, and respective input stations 160IN, e.g., input cells, and output stations 160UT, e.g., load fill sections / cells).For example, in other embodiments, lift modules 150A, 150B are one or more of a vertically reciprocating lift, any suitable automated material handling system, conveyor, bot, turntable, roller bed, or multi-level vertical conveyor (e.g., a paternoster conveyor), operating synchronously or asynchronously. To efficiently utilize each bot 110 in storage and retrieval system 100, a controller, such as control server 120, determines which retrieval aisle the case units 5, 7 are located in. The controller also determines which incoming case unit ICUs should be stored in the retrieval aisle from which the case units 5, 7 (e.g., outgoing case units) are retrieved. The controller sends commands to bots 110 on the level where case units 5, 7 are located to retrieve one or more incoming case unit ICUs from interface stations TS of one or more lift modules 150A ( FIG. 17 , block 1400A), in a manner substantially similar to that described above. The bot 110 grasps the case unit ICU (FIG. 17, block 1420) and transports it to one or more storage spaces 130 in one or more removal aisles 130A2 (FIG. 17, block 1421), with at least one of the removal aisles in which the incoming case unit is located including one of the outgoing case units 5, 7. As can be seen, if the incoming case unit is to be placed in another storage location 130S, the incoming case unit is sorted as described above (FIG. 17, block 1425), and one or more case units are transferred to one case unit holding location, such as a storage space 130S or a buffer (FIG. 17, block 1430), while the untransferred case units are returned to the loading section of the bot 110 for transfer to another case unit holding location (FIG. 17, block 1435).

[0065] As can be appreciated, outgoing case units 5 and 7 may be located in the same or different pick-up aisles and retrieved by one bot 110 or different bots 110, depending on the proximity of the outgoing case units and the predetermined storage location of the incoming case units. For example, referring to FIG. 11 , bot 110 retrieves incoming case unit ICU from interface station TS of lift module 150A (in a manner similar to that described above) for placement in pick-up aisle 130A2, the pick-up aisle in which case unit 5 is located. In this example, case unit 7 is located in pick-up aisle 130A1. After placement of incoming case unit ICU, the bot continues traveling along pick-up aisle 130A2 in a common path (e.g., a single traverse of the pick-up aisle in a single direction) to retrieve outgoing case unit 5 ( FIG. 17 , block 1400). If it is more efficient to have a single robot 110 retrieve multiple case units, the outgoing case unit 5 is positioned on the robot 110 as described above (FIG. 17, block 1405), and the robot moves to the location of another case unit, such as outgoing case unit 7 in aisle 130A1. (Note that if a second outgoing case unit is located in a common aisle with the first outgoing case unit, both outgoing case units are retrieved along a common path in the retrieval aisle by the common transfer arm 110PA (FIG. 6) of the robot 110.) The second outgoing case unit 7 is retrieved by the common transfer arm 110PA (FIG. 17, block 1410), and both case units 5, 7 are transported and placed in one or more of the peripheral buffer stations BS and interface stations TS of a pick-face transport system, such as lift module 150B, in a manner substantially similar to that described above for locating incoming case units (FIG. 17, blocks 1420-1435).After each outgoing case is retrieved (FIG. 17, block 1400), if it would be more efficient to have two different bots 110 retrieve each of case units 5 and 7, the case units are grasped (FIG. 17, block 1420) and transported and placed at one of the peripheral buffer stations BS or interface stations TS of the outgoing lift 150B as described herein (FIG. 17, blocks 1421-1435). In one embodiment, when an outgoing case unit, such as case unit 5, is placed at the peripheral buffer station BS, a different bot 110 from the bot that placed case unit 5 at the peripheral buffer station BS transports case unit 5 to the interface station TS, while in another embodiment, the same bot 110 returns to the peripheral buffer station BS to transport case unit 5 to the interface station TS. In aspects of the disclosed embodiments described herein, the buffer station BS and / or transfer station TS (e.g., at least one pick face transfer station) commonly support pick faces of two or more mixed cases that define a portion of the pick faces of mixed cases exiting the storage array / structure 130 that enter the fulfillment path in a sequence of pick faces ordered based on a predetermined load filling sequence. In one or more aspects of the disclosed embodiments described herein, the buffer station BS and / or transfer station TS form a common pick face transfer interface to the outgoing lift 150B1 such that the commonly supported pick faces are commonly retrieved by the outgoing lift 150B1. In one or more aspects of the disclosed embodiments described herein, the buffer station BS and / or transfer station TS each commonly support two or more mixed case pick faces that define a portion of the pick faces of the mixed cases that are issued from the storage array in a sequence of pick faces ordered based on a predetermined load filling sequence (see, for illustrative purposes only, pick faces 1-4 in FIG. 9 ).In one or more aspects of the disclosed embodiments described herein, the pick faces of the mixed cases commonly supported on the buffer station BS and / or transfer station TS, which define a portion of the pick faces of the mixed cases exiting the storage array / structure 130 in an ordered sequence, are based on the sequence of ordered pick faces on another buffer station BS and / or transfer station TS of another delivery path (see, for example, the mixed cases exiting the exit lift 150B2). In one or more aspects of the disclosed embodiments, any suitable controller, such as controller 120, is configured to communicate with the bot 110 and effect the placement of the pick faces on the buffer station BS and / or transfer station TS based on the sequence of ordered pick faces.

[0066] In one embodiment, the outgoing case units are picked up and transported as a unit (e.g., pick face) by a common transfer arm 110PA (FIG. 6) of the bot 110. Referring again now to FIG. 12, a customer order may request that case unit 7 be transported to output lift 150B1 and that case unit 5 also be transported to output lift 150B1. (Note that in other embodiments, a customer order may request that case units carried by the common bot 110 be transported to different output lifts 150B1, 150B2 (FIG. 9), such that the transfer of case units carried by the common bot 110 to different output lifts occurs in a manner substantially similar to that described herein.) As described above, the controller determines which incoming case unit ICU should be stored in the pick aisle from which case units 5, 7 (e.g., outgoing case units) are picked. The control device sends a command to the bot 110 on the level where the case units 5 and 7 are located to retrieve one or more incoming case units ICU as a whole (e.g., pick faces) from the interface station TS of the lift module 150A in a manner substantially similar to that described above (FIG. 17, block 1400A). The bot 110 grasps the pick face PF1 (FIG. 17, block 1420) and transports the pick face PF1 to the storage space 130 in the retrieval aisle 130A2 (FIG. 17, block 1421). The outgoing case units 5 and 7 are positioned in the storage space 130S and place the pick face PF1 in the storage space 130S (FIG. 17, block 1430). Note that because the entire pick face has been transferred to the common storage space and no case units are left on the bot, the flow does not proceed to block 1435 of FIG. 17 in this example.

[0067] After placing the incoming pick face PF1, the bot 110 continues to move through the aisle 130A2 on a common path (e.g., a single trip down the pick-up aisle in a single direction) to a storage space holding outgoing case units 5 and 7 (positioned adjacent to each other on the storage shelf for simultaneous pick-up as the outgoing pick face PF2). The bot 110 picks up the pick face PF2 using the common transfer arm 110PA (FIG. 6) (FIG. 17, block 1415), grasps the pick face PF2 (FIG. 17, block 1420), and transports the pick face PF2 to the outgoing lift 150B1 (FIG. 17, block 1421). In one embodiment, the case units 5 and 7 of the pick face PF2 are placed together in one of the peripheral buffer stations BS or interface stations TS (FIG. 17, block 1430). In another embodiment, the case units 5 and 7 of the pick face are separated and aligned (in a manner similar to that described above) for placement in different locations (FIG. 17, block 1425). For example, the bot 110 places the case unit 7 in the peripheral buffer station BS (FIG. 17, block 1430), returns the case unit 5 to the loading area of ​​the bot 110 (FIG. 17, block 1435), grasps the case unit 5 (FIG. 17, block 1420), transports the case unit 5 to the interface station TS (FIG. 17, block 1421), and transfers the case unit 5 to the interface station (FIG. 17, block 1430).

[0068] In another embodiment, referring to FIG. 13 , output case units 5 and 7 are removed from different storage locations within a common aisle 130A2 by a common transfer arm 110PA ( FIG. 6 ) of the bot 110. Here, the bot 110 transfers one or more input case units ICU to one or more storage locations in the manner described above, with at least one of the input case units ICU positioned in the common removal aisle 130A2 with the output case units 5 and 7. After placing at least one input case unit in a predetermined storage location 130S in the aisle 130A2, the bot 110 continues to move through the removal aisle 130A1 on the common path of the removal aisle 130A2 and removes a case unit 5 from the storage space 130S1 in the manner described above ( FIG. 17 , block 1400). The case unit 5 is positioned on the bot 110 behind the loading section 110PL as described above ( FIG. 17 , block 1405). The bots 110 continue to move through the removal aisle 130A1 on the common path of the removal aisle and remove the case units 7 from the different storage spaces 130S2 by the common transfer arm 110PA such that both case units 7, 5 are positioned adjacent to each other on the common transfer arm 110PA (FIG. 17, block 1410). As can be appreciated, in one embodiment, the control device 110C is configured to effect removal of the case units in any suitable order, such as, for example, in the reverse order from which the case units were placed.

[0069] In this multiple pick-up example, the case unit holding locations correspond to storage spaces 130S in pick-up aisle 130, but in other embodiments, the case unit holding locations include loading lift modules 150A1, 150A2 (where direct transfer between the bot and the lift occurs), interface or peripheral buffer stations TS, BS for interacting with loading lift modules 150A1, 150A2 (where indirect transfer between the lift modules and the bot occurs), and storage space 130S (note that pick-up by bot 110 from interface station TS and loading lift module 150A is carried into the storage rack array in a just-in-time manner so that case units required for a given order pick-up sequence are not placed in storage space 130S but are transported substantially directly to pick-up lifts 150B1, 150B2).

[0070] The bot 110 grasps both case units 7 and 5 within the loading section 110PL in the manner described above and exits the removal aisle 130A1 (FIG. 17, block 1420). The bot moves along the transfer deck 130B and interacts with the discharge lift 150B1 (FIG. 17, block 1421). The bot separates case units 7 and 5 within the loading section 110PL as described above (FIG. 17, block 1425), in any suitable manner, such as with case unit 7 aligned at the front of the loading section 110PL and case unit 5 aligned at the rear of the loading section 110PL. Case unit 7 is transferred to the peripheral buffer station BS (FIG. 17, block 1430). The bot retracts the transfer arm 110PA and grasps case unit 5 (FIG. 17, block 1420) to return case unit 5 to the loading section 110PL (FIG. 17, block 1435). The case unit 5 is transported to the interface station TS of the output lift 150B1 (FIG. 17, block 1421), aligned with the front of the loading section 110PL as described above (FIG. 17, block 1425), and transported to the transfer station TS as described above (FIG. 17, block 1430). In other embodiments, depending on a predetermined case unit output sequence, the bot 110 places both case units 7 and 5 at a common location / position, such as on one of the output lifts 150B1 and 150B2. For example, the pick face 20 (FIG. 9) on shelf 7000H may include both case units 7 and 5 such that the bot 110 places both case units at a single location on shelf 7000H as a multiple-case unit pick face. As can be appreciated, the case units placed at the buffer station BS are transported to the interface station TS by the bot 110 in one embodiment, or by any suitable conveyor connecting the buffer station BS to the interface station TS in other embodiments.In one aspect, when a case unit is transported by a bot 110 from a buffer station BS to an interface station TS, the transport is a timely transport, for example, such that the bot 110, traveling along a transport deck on a route for another task (e.g., transporting a pick face to a storage section, sorting a pick face, transporting a pick face from a storage section, etc.), travels by the buffer station BS, stops to retrieve a pick face from the buffer station BS, and transports the pick face to the interface station TS while performing the other task.

[0071] An example of a case unit transfer process for a bot 110, including multiple pick-and-place operations of case units with on-the-fly sorting of case units to create a mixed pallet load MPL (shown in FIG. 1F) according to a predetermined order delivery sequence, is described with respect to FIGS. 9 and 24 in accordance with aspects of the disclosed embodiment. The pick face transfer with respect to FIGS. 9 and 24 is substantially similar to that described above with respect to FIGS. 11-13, except that in this aspect, pick face storage is bypassed so that pick faces are transferred substantially directly between the inbound and outbound lifts 150A, 150B1. In one aspect, the bot retrieves a first pick face 5 from a first shelf of a first pick face transfer station, such as transfer station TS of the inbound lift 150A, which transfers one or more pick faces / cases on the pick face transfer station (FIG. 23, block 2300). The bot 110 travels across the transfer deck 130B and buffers the first pick face 5 (or a portion thereof) on a second shelf at a second pick face transfer station, such as the transfer station TS or buffer station BS of the outgoing lift 150B1 (FIG. 23, block 2310). In other embodiments, the first pick face 5 (or a portion thereof) is buffered at the transfer station TS of the outgoing lift 150B1 instead of the buffer station BS. The bot 110 forms a second pick face 5,7 on the second shelf, the second pick face being different from the first pick face 5 and comprising two or more cases in an order sequence corresponding to a predetermined case removal order sequence for mixed cases, and the first pick face 5 and the second pick face 5,7 have at least one case in common (FIG. 23, block 2320). In one embodiment, the lift 150B1 retrieves a second pick face 5, 7 from a second shelf, such as the buffer station BS or the transfer station TS (FIG. 23, block 2330).In one embodiment, the bot 110 forms the second pick face 5, 7 on the fly on the second shelf (e.g., buffer station BS or transfer station TS) during the transfer of the first pick face 5 between the first shelf and the second shelf. In one embodiment, the bot forms the second pick face 5, 7 on board an autonomous guided vehicle. In one embodiment, the bot 110 forms the second pick face 5, 7 on the second shelf or a buffer portion of the second shelf. In one embodiment, the bot 110 places at least a portion of the first pick face (e.g., when the pick face 5 includes two or more cases) retrieved from the first shelf on a storage rack (e.g., storage space 130S) of the storage array before transporting at least a portion of the first pick face to the second shelf. In one embodiment, the second shelf forms a common pick face transfer interface for a vertically reciprocating lift, and the method further includes commonly retrieving the commonly supported pick faces by the vertically reciprocating lift.

[0072] While the bot 110 in FIG. 24 is shown retrieving one case / pick face 5 from the transfer station TS of the inbound lift 150A, in other embodiments, the bot 110 retrieves two (or more) inbound pick faces, such as cases / pick faces 5, 7. Here, in one embodiment, the bot 110 places one pick face 5 on the outbound buffer station BS (or outbound transfer station TS) and then moves to another shelf location (another outbound buffer or transfer station BS, TS, or an adjacent location on the shelf of a common buffer or transfer station BS, TS) to place a second pick face 7. In one embodiment, the lift 150B1 removes the pick faces 5, 7 from the buffer or transfer station BS, TS as described herein. In another embodiment, the bot 110 places both pick faces 5, 7 on the outbound buffer or transfer station BS, TS. Here, the lift 150B1 retrieves one of the pick faces 5, 7 and transports the pick face 5, 7 to the output station 160UT. The lift 150B1 returns to the shelf of the buffer or transfer station BS, TS and retrieves the other pick face 5, 7 for transfer to the output station 160UT. In yet another embodiment, the bot 110 places both pick faces 5, 7 on the shelf of the output buffer or transfer station BS, TS and the lift 150B1 retrieves both pick faces 5, 7 for transfer to the output station 160UT, where the pick faces 5, 7 are singulated or handled together in any suitable manner to build a mixed pallet as shown in FIG. 1F.

[0073] In the examples described herein, the transfer of case units between the bot 110 and the lift 150 occurs passively through the interface station TS as described above. As an example of transfer, referring to FIG. 18 , the autonomous guided vehicle is positioned relative to the interface station TS in a manner similar to that described above with respect to the slats 1210S and / or the positioning features 130F ( FIG. 18 , block 1800). The transfer arm 110PA (e.g., end effector) of the bot 110 extends to transfer a pick face to the interface station TS, where fingers 273A-273E of the transfer arm 110PA interact with, for example, the slats 1210S of the interface station TS ( FIG. 18 , block 1801). As can be appreciated and as described above, multiple pick faces may be positioned on the interface station TS for simultaneous and independent transfer to the lift 150 (e.g., multiple individual pick faces held simultaneously on the interface station). The lift 150 is moved to position the load handling devices LHD, LHDA, and LHDB adjacent to the interface station TS (FIG. 18, block 1802). The load handling devices LHD, LHDA, and LHDB are extended to lift the pick face from the interface station and transfer the pick face to the lift 150, where fingers 4273 of the load handling devices LHD, LHDA, and LHDB interact with slats 1210S of the interface station TS, for example, in the manner described above with respect to FIG. 4B (FIG. 18, block 1803). As can be appreciated, the interface station TS has no moving parts, and the transfer of the pick face between the bot 110 and the lift 150 through the interface station TS is a passive transfer. As can also be appreciated, the transfer of the pick face from the lift 150 to the bot 110 may occur in a manner substantially opposite to that described above with respect to FIG. 18.

[0074] In one embodiment, the pick face constructed by bot 110 (e.g., in the manner described above) to be transported (e.g., placed) to, for example, interface station TS (and / or buffer station BS) is not identical to the pick face retrieved from interface station TS (and / or buffer station BS) by vertical lift 150. For example, referring to FIG. 9, bot 110 constructs a first pick face including individual pick faces 7 and 5 from storage space 130S in rack module RM (e.g., FIG. 2A) (FIG. 19, block 1900). Bot 110 transports and places the first pick face, for example, on shelf 7000B of interface station TS for transfer to vertical lift 150 (FIG. 19, block 1910). As can be appreciated, in this example, individual pick faces 5 and 7 (e.g., forming a first pick face) are placed on a common shelf 7000B for illustrative purposes only, but in other embodiments, individual pick faces 5 and 7 are placed on different shelves 7000A-7000F such that the pick face placed on the shelf by bot 110 is different from the first pick face but includes at least one case unit in common with the first pick face. For example, the first pick face is disassembled such that a different pick face including individual pick face 5 is placed on shelf 7000B, while another different pick face including individual pick face 7 is placed on, for example, shelf 7000H. A vertical lift, such as lift 150B1, retrieves a second pick face from one or more shelves 7000A-7000F (e.g., common to both bot 110 and vertical lift 150B1) of transfer station TS ( FIG. 19 , block 1920). Here, the second pick face is different from the first pick face but includes at least one of the individual pick faces 5, 7 such that at least one case unit is common between the first pick face and the second pick face.

[0075] Similarly, in one embodiment, the pick face transferred (e.g., placed) by the inbound vertical lift 150 (see vertical lift 150A in FIG. 1 ) to, for example, the interface station TS (and / or buffer station BS) is not the same as the pick face removed by the bot 110 from the interface station TS (and / or buffer station BS). In one embodiment, the control server 120 is configured to instruct the bot 110 to cause the classification of cases of the inbound flow (which may also be referred to as warehouse replenishment or inbound stream) at the transfer station TS (and / or buffer station BS) by the bot 110 while the bot 110 forms a pick face, independent of the order in which the cases are removed from the input station by the lift 150. In one embodiment, the bot control device 110C is configured to instruct the bot 110 to cause the classification of cases of the inbound flow at the transfer station TS (and / or buffer station BS) by the bot 110 while the bot 110 forms a pick face, independent of the order in which the cases are removed from the input station by the lift 150. In yet another aspect, both the control server 120 and the bot controller 110C are configured to instruct the bot 110 to cause the bot 110 to classify cases of the inbound flow at the transfer station TS (and / or buffer station BS) while the bot 110 forms a pick face, independent of the order in which the cases are picked up from the receiving station by the lift 150. Thus, the control server 120 and / or the bot controller 110C are configured to set the flow of inbound cases, at least in part, together with the bot 110's classification of cases commonly carried by the bot 110, and separate from the order in which the cases are picked up by the lift 150. For purposes of explanation, this may be referred to as classifying cases of the inbound flow by the bot 110 at the transfer station TS (and / or buffer station BS).For example, referring to FIG. 9A , first pick faces are transferred from input station 160IN by input conveyor 160CB to one or more vertical lifts 150A1, 150A2 ( FIG. 20 , block 2000). In this example, one of the first pick faces includes a combination of individual pick faces 5, 7, while the other first pick face includes a combination of individual pick faces 20, 22. Vertical lift 150A1 places each of first pick faces 5, 7 on shelf 7000B of interface station TS, while vertical lift 150A2 places the other respective first pick face 20, 22 on shelf 7000H of another interface station TS on the same storage level 130L ( FIG. 20 , block 2010). The bot 110 constructs or retrieves a second pick face from the interface station TS such that a first pick face placed on the shelf 7000B, 7000H by the vertical lift 150A1, 150A2 (e.g., common to both the bot 110 and the respective vertical lift 150A) is different from the second pick face, but the second pick face includes at least one case unit in common with the first pick face ( FIG. 20 , block 2020). For example, the first pick faces 5, 7 are disassembled so that a different pick face including the individual pick face 5 (or the individual pick face 7) is retrieved by the bot 110, and / or the other first pick faces 20, 22 are disassembled so that a different pick face including the individual pick face 20 (or the individual pick face 22) is retrieved by the bot 110. Here, the second pick face is different from the first pick face but includes at least one of the individual pick faces of the first pick face such that at least one case unit is common between the first pick face and the second pick face.As can be appreciated, the second pick face may be disassembled by the bot such that the pick face placed on at least one storage shelf by the bot 110 is different from the second pick face, but at least one case unit is common between the second pick face and the pick face placed on at least one storage shelf.

[0076] Output lifts 150B1, 150B2 transport ordered multiple picks placed on shelves 7000A-7000L by bot 110 to output station 160UT according to a predetermined order output sequence. For example, referring again to FIG. 9, pick faces 1-22 are picked by lifts 150B1, 150B2 in an ordered sequence so that they are delivered to output station 160UT in a predetermined order (e.g., as indicated by the numbers associated with each case unit / pick face shown in FIG. 9) necessary to form mixed pallet load MPL (FIG. 1F) and / or to fulfill a predetermined order sequence of items picked in one or more bags, totes, or other containers TOT at operator station 160EP (e.g., to fulfill a customer order). In this manner, the interface stations TS of each lift 150B1, 150B2 each form a buffer that holds one or more case units until they are needed and removed by the respective lift 150B1, 150B2 to form a mixed pallet load.

[0077] In one embodiment, the storage and retrieval system 100 described herein is realized by providing a storage array RMA with rack storage spaces 130S arranged on racks along aisles 130A (FIG. 25, block 2500). At least one transfer deck 130B is also provided that is communicatively connected to each of the aisles 130A (FIG. 25, block 2505). At least one autonomous guided vehicle or bot 110 is provided and is configured to hold at least one pick face and have an extendable effector or transfer arm 110PA for traversing the at least one transfer deck 130B and the aisle 130A to retrieve and place at least one pick face to and from one of the rack storage spaces 130S (FIG. 25, block 2510). A pick face transport axis X, Y of the storage array is defined by the aisle 130A, at least one transfer deck 130B, at least one autonomous guided vehicle 110 traveling thereon, and the extendable effector 110PA so that pick faces are transported along the pick face transport axis X, Y between an input section 160IN of the automated storage and retrieval system where pick faces are input to the storage array and a load filling section 160UT of the automated storage and retrieval system where outgoing pick faces from the storage array are positioned to fill loads according to a predetermined load filling order sequence. On-the-fly sorting of mixed-case pick faces occurs simultaneously with transport on at least one of the pick face transport axes X, Y by the combination of storage racks and autonomous guided vehicles 110 ( FIG. 25 , block 2520), such that two or more of the at least one pick face are retrieved from one or more of the rack storage spaces 130S and placed in one or more pick face holding locations (e.g., transfer or buffer stations TS, BS) distinct from one or more of the rack storage spaces 130S according to a predetermined payload fill order sequence. In one embodiment, a controller 120 (operably connected to at least one autonomous guided vehicle as described above) manages the pick face transport axes X, Y, Z, where the pick face transport axis comprises multiple transport axes.As described above, the plurality of pick face transport axes X, Y, and Z are oriented in at least two directions angled relative to one another. Also as described above, one of the plurality of pick face transport axes Y is defined by the extension of the extendable effector 110PA and is in a different angled direction relative to another one of the plurality of pick face transport axes X, which is defined by the traversal of the autonomous guided vehicle 110 along the pick path 130A. In one embodiment, as described above, on-the-fly sorting is provided by the combination of the rack and at least one autonomous guided vehicle simultaneously with transport on at least one respective one of the plurality of pick face transport axes. In one embodiment, the lift 150 defines another pick face transport axis Z of the storage array. As described herein, on-the-fly sorting of mixed-case pick faces is provided by the lift 150 simultaneously with transport on other pick face transport axes such that two or more of the pick faces are retrieved from one or more deck levels and transported to the load fill section according to a predetermined load fill order sequence.

[0078] 21, 22A, and 22B, in one embodiment, the transfer of pick faces from the loading station 160IN to the unloading station 160UT occurs without the transfer of the pick faces by the bot 110. For example, referring to FIG. 21, the conveyors 160CA, 160CB of the loading and unloading stations 160IN, 160UT are arranged so that each lift 150 serves both the loading and unloading stations 160IN, 160UT. For example, both the conveyor 160CA1 of the loading station 160IN1 and the conveyor 160CB1 of the unloading station 160UT1 are served by the lifts 150A1, 150B1. As can be seen, each conveyor 160CA1, 160CB1 is located at a different level of the common lift 150A1, 150B1 (in a manner similar to that described above with respect to the shelves of the buffer and transfer stations BS, TS) so that a pick face can be removed from the conveyor 160CA1, 160CB1 by the common lift 150A1, 150B1 at one level and transferred to another conveyor 160CA1, 160CB1 at another level. Here, the pick face is transferred by the lift 150A1, 150B1 substantially directly from one conveyor 160CA1, 160CB1 (e.g., from the input station 160IN1 to the output station 160UT1), bypassing the bot 110 and the storage structure 130. As can be seen, in one embodiment, pick faces from input station 160IN1 are placed onto shelf buffer or transfer stations BS, TS by common lifts 150A1, 150B1 for sorting the pick faces as described above before transferring them to output conveyor 160CB1. Referring to Figures 22A and 22B, in one embodiment, pick faces are transferred from input station 160IN to output station 160UT through a buffer lane BL that communicatively connects input conveyor 160CA to output conveyor 160CB, bypassing bot 110 and storage structure 130.

[0079] Referring to FIG. 27 , in accordance with aspects of the disclosed embodiment, storage spaces are provided arranged on racks along a retrieval aisle ( FIG. 27 , block 1600). A multi-level deck is also provided ( FIG. 27 , block 1610), with at least one deck level of the multi-level deck communicating with each aisle, and the multi-level deck and aisle defining a rolling surface for an autonomous guided vehicle at each level of the multi-level deck. Racks at the multiple rack levels are accessed from respective rolling surfaces common to the multiple rack levels ( FIG. 27 , block 1620), with racks arranged along at least one aisle at each level of the multi-level deck. In one aspect, the vertical pitch between rack levels varies for each aisle portion. In one aspect, the vertical pitch between at least two rack levels in each aisle portion is related to another vertical pitch between at least two other rack levels in another aisle portion of each aisle, such that the autonomous guided vehicle performs multiple retrievals in an ordered sequence along a common aisle path. In one aspect, the vertical pitch between at least two rack levels in each aisle portion is related to another vertical pitch between at least two other rack levels in another aisle portion of each aisle such that the vertical pitch and the other vertical pitch substantially fill the vertical space between the multiple deck levels with stored items.

[0080] According to one or more aspects of the disclosed embodiment, an automated storage and retrieval system is provided, the automated storage and retrieval system including at least one autonomous guided vehicle, a transfer deck defining a transport surface for the at least one autonomous guided vehicle, at least one shuttle lift, and first and second pick face interface stations connected to the transfer deck and spaced apart from each other, each pick face interface station communicating with the at least one autonomous guided vehicle on the transfer deck such that pick faces are transferred between the at least one shuttle lift and the at least one autonomous guided vehicle at each pick face interface station. and forming a pick face transfer that interacts with one reciprocating lift, and at least one autonomous transport vehicle is configured to retrieve a first pick face at a first pick face interface station, traverse the transfer deck, and buffer the first pick face or at least a portion thereof at a second pick face interface station such that at least a portion of the first pick face is buffered at the second pick face interface station for transport by the outbound pick face transport system in the order sequence of the pick faces according to the outbound order sequence of the given case of the mixed case pick faces.

[0081] In accordance with one or more aspects of the disclosed embodiment, at least one autonomous guided vehicle is configured to buffer the first pick face, or at least a portion thereof, at a second pick face interface station such that the second pick face interface station has multiple pick faces buffered on a common support.

[0082] In accordance with one or more aspects of the disclosed embodiment, at least one of the plurality of pick faces of the second pick face interface station is different from the first pick face and includes a casing from the first pick face.

[0083] In accordance with one or more aspects of the disclosed embodiment, the autonomous guided vehicle constructs at least one of the plurality of pick faces on the fly at the second pick face interface station during transport of the first pick face between the first pick face interface station and the second pick face interface station.

[0084] In accordance with one or more aspects of the disclosed embodiment, the autonomous guided vehicle builds at least one of the plurality of pick faces on board the autonomous guided vehicle.

[0085] In accordance with one or more aspects of the disclosed embodiment, the autonomous guided vehicle constructs at least one of the plurality of pick faces at the second pick face interface station or at a buffer portion of a common support of a buffer at the second pick face interface station.

[0086] In accordance with one or more aspects of the disclosed embodiment the first pick face is at least one of a plurality of pick faces of a second pick face interface station.

[0087] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes an autonomous guided vehicle access aisle connected to a deck, and a storage array having storage racks arranged on multi-level shelves and distributed along the autonomous guided vehicle access aisle.

[0088] According to one or more aspects of the disclosed embodiment, the autonomous transport vehicle is configured such that at least another portion of the first pick face retrieved from the first pick face interface station is placed on a storage rack of the storage array prior to transport to the second pick face interface station.

[0089] In accordance with one or more aspects of the disclosed embodiment, the second pick face interface station forms a common pick face transfer interface for the at least one reciprocating lift such that a commonly supported pick face is commonly retrieved by the at least one reciprocating lift.

[0090] In accordance with one or more aspects of the disclosed embodiment the transfer deck is non-deterministic and has multiple travel lanes.

[0091] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system is provided, the automated storage and retrieval system including at least one autonomous guided vehicle, a transfer deck defining a transport surface for the at least one autonomous guided vehicle, at least one inbound pick face transport system disposed between an unloading cell and a load loading section, at least one outbound pick face transport system disposed between the unloading cell and the load loading section, and first and second pick face interface stations connected to the transfer deck and spaced apart from each other, each pick face interface station configured to transfer a pick face between a respective one of the inbound pick face transport system and the outbound pick face transport system and the at least one autonomous guided vehicle at each pick face interface station. A pick face transfer is formed at each pick face interface station to interact between at least one autonomous guided vehicle on the transfer deck and each one of the inbound pick face transport system and the outbound pick face transport system, and the at least one autonomous guided vehicle is configured to retrieve a first pick face at a first pick face interface station and traverse the deck, and the second pick face interface station is configured to buffer the first pick face or at least a portion thereof at a second pick face interface station such that the second pick face interface station has multiple pick faces buffered on a common support in an order sequence of the pick faces according to an order sequence of the pick faces of a given case of mixed case pick faces.

[0092] In accordance with one or more aspects of the disclosed embodiment, at least one of the plurality of pick faces of the second pick face interface station is different from the first pick face and includes a casing from the first pick face.

[0093] In accordance with one or more aspects of the disclosed embodiment, the autonomous guided vehicle constructs at least one of the plurality of pick faces on the fly at the second pick face interface station during transport of the first pick face between the first pick face interface station and the second pick face interface station.

[0094] In accordance with one or more aspects of the disclosed embodiment, the autonomous guided vehicle builds at least one of the plurality of pick faces on board the autonomous guided vehicle.

[0095] In accordance with one or more aspects of the disclosed embodiment, the autonomous guided vehicle constructs at least one of the plurality of pick faces at the second pick face interface station or at a buffer portion of a common support of a buffer at the second pick face interface station.

[0096] In accordance with one or more aspects of the disclosed embodiment the first pick face is at least one of a plurality of pick faces of a second pick face interface station.

[0097] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes an autonomous guided vehicle access aisle connected to a deck, and a storage array having storage racks arranged on multi-level shelves and distributed along the autonomous guided vehicle access aisle.

[0098] According to one or more aspects of the disclosed embodiment, the autonomous transport vehicle is configured such that at least another portion of the first pick face retrieved from the first pick face interface station is placed on a storage rack of the storage array prior to transport to the second pick face interface station.

[0099] In accordance with one or more aspects of the disclosed embodiment, the second pick face interface station forms a common pick face transfer interface for each one of the incoming pick face transport system and the outgoing pick face transport system such that a commonly supported pick face is commonly retrieved by each one of the incoming pick face transport system and the outgoing pick face transport system.

[0100] In accordance with one or more aspects of the disclosed embodiment the transfer deck is non-deterministic and has multiple travel lanes.

[0101] In accordance with one or more aspects of the disclosed embodiment, a method for automated storage and retrieval is provided, the method including: retrieving, by an autonomous guided vehicle, a first pick face from a first shelf of a first pick face transfer station; buffering, by the autonomous guided vehicle, the first pick face on a second shelf of a second pick face transfer station; forming a second pick face on the second shelf, the second pick face being different from the first pick face and comprising two or more cases in an order sequence corresponding to a predetermined case unloading order sequence for mixed cases, the first pick face and the second pick face forming the second pick face having at least one case in common; and retrieving, by a reciprocating lift, the second pick face from the second shelf.

[0102] According to one or more aspects of the disclosed embodiment, the method includes forming, by the autonomous guided vehicle, a second pick face on the fly on a second shelf during transport of a first pick face between the first shelf and the second shelf.

[0103] In accordance with one or more aspects of the disclosed embodiment, the method includes loading, by the autonomous guided vehicle, the second pick face onto the autonomous guided vehicle.

[0104] In accordance with one or more aspects of the disclosed embodiment, the method includes forming, by the autonomous guided vehicle, a second pick face at a second shelf or at a buffer portion of the second shelf.

[0105] According to one or more aspects of the disclosed embodiment, the method includes placing, by the autonomous guided vehicle, at least a portion of a first pick face retrieved from a first shelf on a storage rack of a storage array before transporting the at least a portion of the first pick face to a second shelf.

[0106] In accordance with one or more aspects of the disclosed embodiment, the second shelf forms a common pick face transfer interface for the reciprocating lift, and the method further includes commonly retrieving the commonly supported pick faces by the reciprocating lift.

[0107] According to one or more aspects of the disclosed embodiment, an automated storage and retrieval system is provided, the automated storage and retrieval system including: a storage array having rack storage spaces arranged on racks along an aisle; at least one transfer deck communicatively connected to each of the aisles; and at least one autonomous guided vehicle configured to hold at least one pick face and traverse the at least one transfer deck and the aisles, the at least one autonomous guided vehicle having an extendable effector for placing the at least one pick face into one of the rack storage spaces and retrieving the at least one pick face from one of the rack storage spaces, wherein the aisle, the at least one transfer deck, the at least one autonomous guided vehicle traversing thereover, and the extendable effector define a pick face transport axis of the storage array, and the pick face is configured to transfer the pick face to and from the storage array. The racks and autonomous guided vehicles are configured to be combined to provide on-the-fly sorting of mixed case pick faces simultaneously with transport on at least one of the pick face transport axes, such that two or more of the at least one pick face are retrieved from one or more of the rack storage spaces and placed in one or more pick face holding locations that are different from one or more of the rack storage spaces according to the predetermined load fill order sequence, and are transported along the pick face transport axis between an receiving section of the automated storage and retrieval system where receiving of the mixed case pick faces occurs and a load fill section of the automated storage and retrieval system where outgoing pick faces from the storage array are positioned to fill the load according to a predetermined load fill order sequence.

[0108] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes a controller operably connected to at least one autonomous guided vehicle and configured to manage a pick face transport axis, the pick face transport axis comprising a plurality of transport axes.

[0109] In accordance with one or more aspects of the disclosed embodiment the plurality of pick face transport axes are oriented in at least two directions that are angled relative to one another.

[0110] In accordance with one or more aspects of the disclosed embodiment, one of a plurality of pick face transport axes defined by the extension of the extendable effector is in a different, angled direction relative to another of a plurality of pick face transport axes defined by the movement of the autonomous guided vehicle along the path.

[0111] In accordance with one or more aspects of the disclosed embodiment, the rack and at least one autonomous guided vehicle combine to provide on-the-fly sorting concurrently with transport on at least one of each of a plurality of pick face transport axes.

[0112] In accordance with one or more aspects of the disclosed embodiment the at least one transfer deck comprises two or more transfer decks disposed at different deck levels.

[0113] In accordance with one or more aspects of the disclosed embodiment, the automated storage and retrieval system includes a lift communicatively connected to each of the decks at the different deck levels, the lift configured to transport pick faces between the different deck levels and defining another pick face transport axis of the storage array.

[0114] According to one or more aspects of the disclosed embodiment, the lift is configured to provide on-the-fly sorting of mixed case pick faces simultaneously with transport on other pick face transport axes such that two or more pick faces are retrieved from one or more deck levels and transported to a load filling section according to a predetermined load filling order sequence.

[0115] In accordance with one or more aspects of the disclosed embodiment, on-the-fly sorting is effected simultaneously with transport on at least one of each of a plurality of pick face transport axes and each of the other transport axes of the lift.

[0116] According to one or more aspects of the disclosed embodiment, an automated storage and retrieval system is provided, the automated storage and retrieval system including: a storage array having rack storage spaces arranged on racks along an aisle; at least one transfer deck communicatively connected to each of the aisles; at least one autonomous guided vehicle configured to hold at least one pick face and traverse the at least one transfer deck and the aisles, the at least one autonomous guided vehicle having an extendable effector for placing the at least one pick face into one of the rack storage spaces and retrieving the at least one pick face from one of the rack storage spaces; and at least one lift communicatively connected to each transfer deck and configured to transport the pick face to and from the at least one transfer deck, wherein the aisle, the at least one transfer deck, the at least one autonomous guided vehicle traversing thereover, the extendable effector, and the at least one lift define a pick face transport axis of the storage array, and the pick face is an automated storage array along which the pick face is inserted into the storage array. the racks and autonomous guided vehicles are configured to combine to provide on-the-fly sorting of mixed-case pick faces on at least one of the pick face transport axes, such that two or more of the at least one pick face are retrieved from one or more of the rack storage spaces and placed in one or more pick face holding locations different from one or more of the rack storage spaces according to the predetermined load fill order sequence; and the at least one lift is configured to transport two or more of the pick faces from other of the at least one transfer deck and transport them to the load fill section according to the predetermined load fill order sequence along the pick face transport axis.configured to provide on-the-fly sorting of mixed-case pick faces, the on-the-fly sorting being provided simultaneously with transport on at least one of the respective pick face transport axes;

[0117] In accordance with one or more aspects of the disclosed embodiment, an automated storage and retrieval system includes a controller operably connected to at least one autonomous guided vehicle and at least one lift and configured to manage a pick face transport axis.

[0118] In accordance with one or more aspects of the disclosed embodiment the pick face transport axis is oriented in at least two directions that are angled relative to one another.

[0119] In accordance with one or more aspects of the disclosed embodiment, one of the pick face transport axes defined by the extension of the extendable effector is in a different, angled direction relative to another of the pick face transport axes defined by the movement of the autonomous guided vehicle along the path.

[0120] In accordance with one or more aspects of the disclosed embodiment, the rack and at least one autonomous guided vehicle are combined to provide on-the-fly sorting concurrently with transport on at least one of the pick face transport axes.

[0121] In accordance with one or more aspects of the disclosed embodiment, the at least one transfer deck comprises two or more transfer decks disposed at different deck levels, and the at least one lift is configured to transport the pick faces between the different deck levels.

[0122] In accordance with one or more aspects of the disclosed embodiment, a method for automated storage and retrieval is provided, the method including: providing a storage array having rack storage spaces arranged on racks along aisles; providing at least one transfer deck communicatively connected to each of the aisles; at least one autonomous guided vehicle configured to hold at least one pick face and traverse the at least one transfer deck and the aisles, the at least one autonomous guided vehicle having an extendable effector for placing the at least one pick face into one of the rack storage spaces and retrieving the at least one pick face from one of the rack storage spaces; and providing an inbound section of the automated storage and retrieval system where the pick face is received by the storage array and where the pick face is retrieved from the storage array in accordance with a predetermined load fill order sequence. The method includes defining a pick face transport axis of the storage array by an aisle, at least one transfer deck, at least one autonomous guided vehicle traveling thereon, and an extendable effector so that the pick faces are transported along the pick face transport axis to and from a load filling section of the automated storage and retrieval system arranged to fill the load, and providing on-the-fly sorting of the mixed case pick faces simultaneously with transport on at least one of the pick face transport axes by a combination of the rack and the autonomous guided vehicle such that two or more of the at least one pick face are retrieved from one or more of the rack storage spaces and placed in one or more pick face holding positions different from one or more of the rack storage spaces according to a predetermined load filling order sequence.

[0123] In accordance with one or more aspects of the disclosed embodiment, a method includes managing a pick face transport axis by a controller operably connected to at least one autonomous guided vehicle, the pick face transport axis including a plurality of transport axes.

[0124] In accordance with one or more aspects of the disclosed embodiment the plurality of pick face transport axes are oriented in at least two directions that are angled relative to one another.

[0125] In accordance with one or more aspects of the disclosed embodiment, one of a plurality of pick face transport axes defined by the extension of the extendable effector is in a different, angled direction relative to another of a plurality of pick face transport axes defined by the movement of the autonomous guided vehicle along the path.

[0126] In accordance with one or more aspects of the disclosed embodiment, the method includes providing on-the-fly sorting concurrently with transport on at least one of each of a plurality of pick face transport axes by a combination of a rack and at least one autonomous guided vehicle.

[0127] In accordance with one or more aspects of the disclosed embodiment, the method includes defining another pick face transport axis of the storage array by a lift communicatively connected to each of at least one transfer deck disposed on the different deck levels and transporting pick faces between the different deck levels.

[0128] According to one or more aspects of the disclosed embodiment, the method includes effecting on-the-fly sorting of mixed case pick faces by a lift simultaneously with transport on other pick face transport axes such that two or more pick faces are removed from one or more deck levels and transported to a load filling section according to a predetermined load filling order sequence.

[0129] In accordance with one or more aspects of the disclosed embodiment, the method includes providing on-the-fly sorting concurrently with transport on at least one of each of a plurality of pick face transport axes and each of the other transport axes of the lift.

[0130] It should be understood that the above description is merely illustrative of aspects of the disclosed embodiments. Various alternatives and modifications may be devised by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, the aspects of the disclosed embodiments are intended to embrace all such alternatives, modifications, and variations that fall within the scope of the appended claims. Furthermore, the fact that different features are recited in respective different dependent or independent claims does not mean that a combination of these features cannot be advantageously used; such combinations remain within the scope of the present invention.

Claims

1. 1. An automated storage and retrieval system comprising: at least one autonomous guided vehicle; an elevated transfer deck at a level elevated from an output conveyor at a lower level and defining a transport surface for the at least one autonomous guided vehicle; a first pick face interface station and a second pick face interface station connected to the transfer deck and spaced apart from each other; Equipped with Each pick face interface station forms a pick face transfer interface between the at least one autonomous guided vehicle on the transfer deck and a lower transfer section at each of the second pick face interface stations, whereby a pick face is transferred from the at least one autonomous guided vehicle via the lower transfer section at each of the second pick face interface stations; the at least one autonomous guided vehicle is configured to engage a first pick face at the first pick face interface station, traverse the transfer deck, and transfer the first pick face, or at least a portion thereof, via the downward transfer section at the second pick face interface station, the second pick face interface station having a plurality of pick faces that are downwardly transferred in an order sequence of pick faces that defines a continuous structured sequence of the ordered plurality of pick faces, the continuous structured sequence embodying a predetermined pick face delivery order sequence dependent on a predetermined pick face delivery order sequence of mixed product pick faces, the predetermined pick face delivery order sequence having a predetermined continuous structured sequence of ordered mixed product pick faces; Automated storage and retrieval system.

2. 2. The automated storage and retrieval system of claim 1, wherein the autonomous guided vehicle sequences at least one of the plurality of pick faces by the descending transfer at the second pick face interface station to form the predetermined pick face outgoing order sequence having the predetermined continuous structured sequence on the outgoing conveyor.

3. The automated storage and retrieval system of claim 1 , wherein the first pick face is at least one of the plurality of pick faces of a mixed load at the second pick face interface station.

4. said automated storage and retrieval system comprising: an autonomous guided vehicle access aisle connected to the transfer deck; a storage array having storage racks arranged on multi-level shelves and distributed along an access path for the autonomous guided vehicle; The automated storage and retrieval system of claim 1 further comprising:

5. 5. The automated storage and retrieval system of claim 4, wherein the autonomous transport vehicle is configured such that at least another portion of the first pick face engaged at the first pick face interface station is placed in a storage rack of the storage array before transport to the second pick face interface station.

6. 2. The automated storage and retrieval system of claim 1, wherein the descending transfer section is a reciprocating lift, and the second pick face interface station forms a common pick face transfer interface with the at least one reciprocating lift such that pick faces commonly supported at the second pick face interface station are commonly transported by the at least one reciprocating lift.

7. The automated storage and retrieval system of claim 1 , wherein the transfer deck has a non-deterministic conveying surface and has multiple travel lanes.

8. 1. An automated storage and retrieval system comprising: at least one autonomous guided vehicle; an elevated transfer deck defining a transport surface for the at least one autonomous guided vehicle; at least one inbound pick face transport system disposed between the unloading cell and the load filling section; at least one outgoing pick face transport system disposed between the unloading cell and the load filling section, the elevated transfer deck being at an elevated level relative to the outgoing pick face transport system; a first pick face interface station and a second pick face interface station connected to the transfer deck and spaced apart from each other; Equipped with Each pick face interface station forms a pick face transfer interface between the at least one autonomous guided vehicle on the transfer deck and a lower transfer section at each of the second pick face interface stations, whereby a pick face is transferred from the at least one autonomous guided vehicle via the lower transfer section at each of the second pick face interface stations; the at least one autonomous guided vehicle is configured to engage a first pick face at the first pick face interface station, traverse the transfer deck, and transfer the first pick face or at least a portion thereof via the downward transfer at the second pick face interface station, wherein at least a portion of the first pick face is downwardly transferred in an order sequence of pick faces that defines a continuous structured sequence of ordered pick faces, the continuous structured sequence embodying a predetermined pick face delivery order sequence dependent on a predetermined pick face delivery order sequence of mixed product pick faces, and the predetermined pick face delivery order sequence has a predetermined continuous structured sequence of ordered mixed product pick faces; Automated storage and retrieval system.

9. 9. The automated storage and retrieval system of claim 8, wherein the autonomous guided vehicle sequences at least one of the plurality of pick faces by the descending transfer at the second pick face interface station to form the predetermined pick face outgoing order sequence having the predetermined continuous structured sequence on an outgoing conveyor.

10. The automated storage and retrieval system of claim 8 , wherein the first pick face is at least one of the plurality of pick faces of a mixed load at the second pick face interface station.

11. said automated storage and retrieval system comprising: an autonomous guided vehicle access aisle connected to the transfer deck; a storage array having storage racks arranged on multi-level shelves and distributed along an access path for the autonomous guided vehicle; The automated storage and retrieval system of claim 8 further comprising:

12. 12. The automated storage and retrieval system of claim 11, wherein the autonomous transport vehicle is configured to place at least another portion of the first pick face engaged at the first pick face interface station on a storage rack of the storage array prior to transport to the second pick face interface station.

13. 9. The automated storage and retrieval system of claim 8, wherein the downward transfer section is a reciprocating lift, and the second pick face interface station forms a common pick face transport interface for each one of the incoming pick face transport system and the outgoing pick face transport system such that a pick face commonly supported at the second pick face interface station is commonly transported by each one of the incoming pick face transport system and the outgoing pick face transport system.

14. The automated storage and retrieval system of claim 8 , wherein the transfer deck has a non-deterministic conveying surface and has multiple travel lanes.

15. engaging, by the autonomous guided vehicle, a first pick face from a first shelf at a first pick face transfer station; transferring the first pick face onto a second shelf of a second pick face transfer station by the autonomous guided vehicle; forming a second pick face on the second shelf, the second pick face being different from the first pick face and including a plurality of pick faces that are downwardly transported in an order sequence of pick faces that defines a continuous structured sequence of the ordered plurality of pick faces, the continuous structured sequence embodying a predetermined pick face delivery order sequence dependent on a predetermined pick face delivery order sequence of mixed commodities, the predetermined pick face delivery order sequence having a predetermined continuous structured sequence of ordered mixed commodities, and the first pick face and the second pick face having at least one commodity in common; transferring the second pick face from the second shelf by a descending transfer section; A method comprising:

16. 16. The method of claim 15, further comprising sequencing, by the autonomous guided vehicle, the second pick faces on the second shelf to form the predetermined pick face outbound order sequence having the predetermined continuous structured sequence on an outbound conveyor.

17. 16. The method of claim 15, further comprising placing, by the autonomous guided vehicle, at least a portion of the first pick face engaged at the first shelf on a storage rack of a storage array before transporting at least a portion of the first pick face to the second shelf.

18. 16. The method of claim 15, wherein the downward transfer section is a reciprocating lift, the second shelf forms a common pick face transfer interface with the reciprocating lift, and the method further includes commonly transporting pick faces commonly supported on the second shelf by the reciprocating lift.

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