Goods storage and order fulfillment system with a container storage and without fixed conveyors

Abstract

Goods storage and order fulfillment system without a fixed conveyor system comprising at least one autonomous transport unit for retrieving or transferring of containers from or to a storage and retrieval machine in order to transport containers to and from a picking station, wherein the autonomous transport unit is designed as a floor-bound conveying means with its own travel drive and which is automatically controlled and guided in a contactless manner; - the autonomous transport unit having a mobile shelf unit with shelves arranged vertically one above the other for at least one container for the simultaneous transport of a plurality of containers; - and with at least one picking station which is supplied by the autonomous transport unit by means of the mobile shelf unit with containers for at least partial order fulfillment on the basis of order data.

Description

[0001] Goods storage and order fulfillment system with a container storage and without fixed conveyors

[0002] The invention pertains to a goods storage and order fulfillment system without a fixed conveyor system according to claim 1.

[0003] It is well known to use warehouses to store goods for use in order fulfilment. In most cases, a distinction is made between high-bay warehouses and automated smallparts or shelf storage systems connected to picking stations, both of which have in common that they comprise permanently installed and thus predefined structures. Thus, for their design, it must be known what the maximum demand for storage space, throughput, etc. will be and how this will change in the course of operation, in order to take into account an optimized design in the construction, since this cannot easily be changed later.

[0004] In addition, warehouses with mobile shelves are also known from the company Kiva. For example, EP 1 590 272 A2 describes a system for a warehouse respective a system for inventory management in a warehouse comprising one or more mobile drive units and a plurality of movable storage magazines, each movable storage magazine being a shelf-like structure containing articles and configured for attachment via a coupling mechanism to the mobile drive units, wherein the mobile drive unit couples to a movable storage magazine and lifts to transport the movable storage magazine in response to command signals through the department store to picking stations where picking is performed directly from the storage magazines.

[0005] Such a system is quick to implement in a warehouse and is readily scalable to increase performance as needed. However, space utilization is poor and the mobile storage magazines are ergonomically unfavorable, as the items contained in the storage magazines are arranged at a wide variety of levels / heights and the picker must bend and / or stretch or even use a ladder to reach all items. In addition, replenishing the storage magazines is laborious.

[0006] In addition, mixed forms are known in which mobile racks are combined with permanently installed infrastructure. For example, EP 2 353 778 A2 discloses a shelf magazine for storing and transferring tools for use in a machine tool. The shelf magazine is provided with at least one shelf base frame with a plurality of shelf compartments, wherein each shelf compartment can be assigned a laterally insertable receiving device, and wherein each receiving device has at least one tool receiving structure for the safe storage of a tool. It further comprises a lifting unit for receiving a receiving device pushed out of the shelf compartment and for vertically displacing the receiving device, and a transfer unit for receiving / delivering the tool from / to the receiving device and for further handling of the tool.

[0007] EP 2 670 647 A1 describes a so-called shuttle warehouse, in which shuttles travel in the aisles between shelves of a rack warehouse in the storage levels as single-level storage and retrieval machines for lateral storage and retrieval of containers into and out of the shelves.

[0008] WO 2021 / 078191 A1 discloses a robotic vehicle comprising a mobile shelving unit with a load handling device for transporting goods.

[0009] In contrast, it is the objective of the present invention, to provide a goods storage and order fulfillment system that is highly versatile and redundant and should use fixed installations as few as possible.

[0010] This objective is solved by the goods storage and order fulfillment system set forth in claim 1. Advantageous embodiments result from the subclaims and the description.

[0011] According to the invention it has been recognized that if the goods storage and order fulfillment system does not have fixed classical conveyors to connect the different functional zones, i. e. storage zone and order fulfilment zone, but makes use of autonomous transport units, it becomes possible to achieve a higher flexibility. However, such flexibility may be constrained by a bottle neck if too many autonomous transport units gather or jam in front of the storage when needing access to the storage at the same time. To solve this aspect, the invention combines autonomous transport units with mobile shelves to reduce the number of autonomous transport units necessary by increasing the transport capacity through use of the shelves.

[0012] In other words, the invention provides a goods storage and order fulfillment system without a fixed conveyor system

[0013] - with a rack storage system having storage locations for goods containers; - with at least one automated storage and retrieval machine of the rack storage system for storing and retrieving containers into and from the storage locations of the rack storage system;

[0014] - with at least one autonomous transport unit for retrieving or transferring of containers from or to the storage and retrieval machine in order to transport containers to and from a picking station, wherein the autonomous transport unit is designed as a floorbound conveying means with its own travel drive and which is automatically controlled and guided in a contactless manner;

[0015] - the autonomous transport unit having a mobile shelf unit with shelves arranged vertically one above the other for at least one container for the simultaneous transport of a plurality of containers;

[0016] - and with at least one picking station which is supplied by the autonomous transport unit by means of the mobile shelf unit with containers for at least partial order fulfillment on the basis of order data.

[0017] In the present context "without fixed conveyor" means that there is no fixed conveyor transport means installed within the storage for essentially horizontal transport of containers between areas.

[0018] The containers or load carriers can be containers, trays, boxes etc. as known in the prior art.

[0019] The autonomous transport unit and the mobile shelf unit may be permanently fixed together or separably connected.

[0020] In an embodiment the picking station uses a loading and unloading unit for loading and unloading the mobile shelf unit. Such a loading and unloading unit may displace the containers from the mobile shelves by push-pull mechanisms, robotic grippers or driven conveyors. The picking station itself will include conveyors sourced from the loading and unloading unit and conveyors feeding back into the loading and unloading unit. Beneficially the such conveyors will form a loop which in turn form a picking location for the human operator (picker) or robotic picking device.

[0021] The loading and unloading unit for loading and unloading the mobile shelf unit may be fixed or integrated with the picking station. Alternatively, the loading and unloading unit itself may also be mobile and positioned dynamically based on need. The loading and unloading unit may be implemented with a lift for accessing the different levels of the mobile shelves and use push-pull devices to actively displace the containers from and to the shelves or picking station. The list may interface with the conveyors of the picking station.

[0022] Alternatively, the picking station may be “virtually” formed by arranging mobile shelves with source containers and mobile shelves with order containers such that they are both accessible for the human operator (picker) or robotic picking device.

[0023] In an embodiment the vertically stacked shelves of the mobile shelf have actively driven conveying means and optionally a load handling means for containers. Alternatively, the vertically stacked shelves of the mobile shelf are passive.

[0024] For exchange of the containers at the storage, the vertically stacked shelves of the mobile shelf may be loaded and unloaded by the automated storage and retrieval machine of the rack storage itself. Such automated storage and retrieval machine may be of the shuttle type and include a container carrying area between a front and back housing and equipped with container handling means for loading and unloading, such as telescopic rails equipped with selectively engageable or swivable fingers.

[0025] The frontal part of the racks may have an empty space corresponding to the size of the autonomous transport unit together with the mobile shelf unit and the autonomous transport unit carrying the mobile shelf unit may therefore enter a rack from the front side and optionally deposit the mobile shelf.

[0026] The vertically stacked shelves of the mobile shelf may be loaded and unloaded by rack conveyors arranged in the frontal part of the racks. Such conveyors would be integrated into the footprint of a rack on lower levels and allow the automated storage and retrieval machine to drop-off or pick-up containers for decoupling.

[0027] The autonomous transport unit may drive into the storage rack, i. e. into an aisle between racks, for accessing the rack conveyors arranged in the frontal part of the racks on lower levels for drop-off or pick-up of containers from or to a mobile shelf being carried. Alternatively, the autonomous transport unit may approach the storage rack from the front (not entering the aisle) for accessing the rack conveyors arranged in the frontal part of the racks on lower levels for drop-off or pick-up of containers from or to a mobile shelf being carried.

[0028] In an embodiment, the height of the mobile shelf unit may coincide with the height of the racks.

[0029] The shelves of the mobile shelf will be on the same level as the storage locations.

[0030] The rack storage system may be a shuttle storage having multi-level racks, that share an aisle between them and shuttles travel the length of the aisle as single level handling automated storage and retrieval machines. The containers may be exchanged vertically by lifts arranged adjacent the rack conveyors and drop-off or pick-up containers for decoupling from the rack conveyors.

[0031] The rack storage system maybe a container-lift-free shuttle storage having multi-level racks, that share an aisle between them and shuttles travel the length of the aisle as single level handling automated storage and retrieval machines, and are additionally implemented to travel vertically between to uprights.

[0032] In the present context "container-lift-free" means that there is no fixed vertical transport means installed within the storage for vertical transport of containers between storage levels. The shuttles will be implemented to additionally travel vertically or climb the racks.

[0033] In a preferred embodiment, the climbing means of the storage and retrieval apparatus includes a set of four climbing wheels for interaction with the vertical climbing rails, the four climbing wheels having a perpendicular axis of movement in comparison to the four travelling wheels and the four climbing wheels being retractable between an extended engaging position for interaction with the vertical climbing rails and a retracted non-engaging position while travelling horizontally along the running rails horizontally along the respective storage rack level. Such climbing wheels can be retrofitted to known storage and retrieval apparatus. Each storage and retrieval apparatus may have a second set of four or more retractable traveling wheels for traveling along direction change rails horizontally along the respective storage rack level of an aisle in the area of the vertical climbing rails; two wheels per set on each side of the storage and retrieval apparatus, one or both of each side being driven, e. g. on a joint driven axis, for use while changing the direction of movement of the storage and retrieval apparatus from a vertical movement along the vertical climbing rails to a horizontal movement along the running rails of a respective storage rack level of an aisle.

[0034] The four traveling wheels for traveling along direction change rails horizontally along the respective storage rack level of an aisle in the area of the vertical rails are preferably retractable wheels and are controlled to be extracted or extended to the use position whilst the storage and retrieval apparatus is traveling along the direction change rails. Their position on the storage and retrieval apparatus is such that their distance and placement allow interaction with the direction change rails when changing direction of travel.

[0035] Direction change rails may be arranged between the vertical climbing rails on each level having running rails and the running rails of a respective storage rack level of an aisle may then have a gap to the direction change rails horizontally along the respective storage rack level of an aisle in the area of the respective vertical rail. This allows an easy and smooth change of direction from vertical to horizontal movement (or vice versa).

[0036] So essentially, the storage and retrieval apparatus would climb up the vertical climbing rails by use of its extended climbing wheels. As soon as it reaches its destination level, the traveling wheels for traveling along direction change rails are extended to engage the direction change rails. The climbing wheels can then be retracted. The storage and retrieval apparatus will travel horizontally along these rails (just a few centimeters) until the first set of four traveling wheels for traveling along the running rails horizontally engage the horizontal aisle running rails, whereas the auxiliary traveling wheels for traveling along direction change rails loose traction and may be retracted.

[0037] Beneficially, the running rails and the direction change rails are aligned with each other. Preferably, they both have a C-shaped cross section, of which the top surface forms support for the first set of traveling wheels and the inner lower surface forms a support for the second set of traveling wheels.

[0038] Additionally, it is possible to implement cross aisle running rails to form a bridge perpendicular to aisle direction for movement of each storage and retrieval apparatus between aisles, preferably propelled by the set of the four climbing wheels. Then it is even possible for the storage and retrieval apparatus to change aisles without leaving the racking.

[0039] In one possible embodiment, the climbing wheels are gear wheels (pinion) and the vertical rails and / or cross aisle running rails have corresponding linear gears (racks) or chains, with which a positive interaction occurs.

[0040] In an embodiment the gear wheels (pinion) may be implemented as self-locking (e. g. by self-weight of the storage and retrieval apparatus) so as to stop a storage and retrieval apparatus in the event of (a power) failure from uncontrolled vertical travel or crash. To do so the gear wheels may be attached by pivoting arms to the frame of the storage and retrieval apparatus such that it implements a wedge-like function. Additionally, the gear wheels may be equipped with a mechanical failsafe brake, which would hold a storage and retrieval apparatus in a current position even if power or control is lost as long as pinions are locked.

[0041] Obviously, it is also possible to use different climbing means. For example, the climbing wheels could also be implemented as wheels that are pressed against vertical rails with enough force to produce a friction high enough to not slide downwards, even when the load carrying area is loaded.

[0042] The storage facility may include a direct horizontal exchange of load units taking place from one aisle to an adjacent aisle via exchange locations within the storage racks, wherein the storage and retrieval apparatus itself actively horizontally moves the transportation units in the exchange locations using the unit (or load) handling means, preferable telescopic arms having engageable unit (or load) contacting means (i. e. rotatable or linear moveable fingers). In this way load units may be transferred from one aisle to the adjacent aisle on the shortest path, without need for them to leave an aisle or for the storage and retrieval apparatus to do so.

[0043] Alternatively, the rack storage system may comprise a grid of uprights in which containers are stored besides and above each other and are to be retrieved and stored from above by robotic storage and retrieval carts, that travel on the top of the grid. Such storage systems are known from Autostore as described in e.g. WO 2014 / 090684 A1.

[0044] The rack storage system may include a storage arrangement as in WO 2020 / 210558 A1 comprising a grid of uprights in which containers are stored besides and above each other and are to be retrieved and stored from above by robotic storage and retrieval carts, that travel on the top of the grid, as before, but having elevator shafts for accessing the containers from the side. The rack storage system, may include a loading and unloading station for the mobile shelves serviced by robotic storage and retrieval carts.

[0045] The use of autonomous mobile robots (AMR) and / or automated guided vehicles (AGV) as the autonomous transport units allows for flexible use of available space and change of routing when needed in contrast to structured technology (fixed infrastructure).

[0046] Automated guided vehicles (AGV) are defined as mobile self-driving transportation platforms that usually follow given routes e. g. along marked long lines or wires on the floor, or uses radio waves, vision cameras, magnets, or lasers for navigation and transport objects, usually - but not limited to - in the form of pallet loads. They have the ability to automatically move and pick objects in manufacturing facilities and distribution centers, warehouses based on predefined routes etc.

[0047] An autonomous mobile robot (AMR) is similar to an AGV. An AMR is usually more sophisticated than an AGV and is able to navigate dynamically as well as plan its own path. It is usually equipped with on board devices to understand & react to the operating environment. This gives it a high flexibility in multiple order fulfillment use applications.

[0048] They both transport containers to and from a location with the help of the mobile shelves or a single container directly. The mobile shelves may be separate or fixed to the AGV or AMR. If they are separate the AGV or AMR may comprise a lifting platform for engaging a mobile shelf from below for lifting it off the ground and supporting it during transportation. The lifting platform may be mechanically, pneumatically or hydraulically driven.

[0049] The AGV or AMR may contain a rotatable unit to change the orientation of a supported mobile shelf. It may also be tiltable under the control of a controller to counter shelf movement during transport based on sensor input.

[0050] Further details of the invention will be apparent from the following description of examples of embodiments based on the drawings, in which

[0051] Fig. 1 shows a schematic perspective view of a goods storage and order fulfillment system without a fixed conveyor system with a generic storage;

[0052] Fig. 2 shows a schematic perspective view of a goods storage and order fulfillment system without a fixed conveyor system and with a lift-free storage;

[0053] Fig. 3 shows a schematic perspective view of a goods storage and order fulfillment system without a fixed conveyor system with a shuttle storage;

[0054] Fig. 4 shows a schematic perspective of figure 2 showing unloading and loading of mobile shelves at the racking;

[0055] Fig. 5 shows a schematic perspective of figure 2 showing an alternative unloading and loading of mobile shelves at the racking;

[0056] Fig. 6 shows a schematic perspective of figure 2 showing a further alternative unloading and loading of mobile shelves at the racking;

[0057] Fig. 7 shows a schematic perspective of figure 2 showing again a further alternative unloading and loading of mobile shelves at the racking;

[0058] Fig. 8 shows a schematic perspective of figure 7 in the whole context detailing interaction between the storage, picking stations, loading and unloading units, mobile shelves and AMR;

[0059] Fig. 9 shows a schematic perspective of figure 7 in the whole context detailing interaction between the storage, alternative picking stations, mobile shelves and AMR;

[0060] Fig. 10 shows a schematic perspective of figure 4 in the whole context detailing interaction between the storage, alternative picking stations, mobile shelves and AMR;

[0061] Fig. 11 shows a schematic perspective of an alternative to figure 7 wherein the mobile shelf is fixed to the AMR showing interaction between the climber shuttle and mobile shelf and AMR;

[0062] Fig. 12 shows a schematic perspective of an alternative to figure 4 wherein the alternative AMR transports a single container showing interaction between the rack conveyor and AMR;

[0063] Fig. 13 shows a schematic perspective of two alternative versions, fixed and mobile, of a loading and unloading unit;

[0064] Fig. 14 shows a schematic perspective of further details of a fixed loading and unloading unit of figure 13;

[0065] Fig. 15 shows a schematic perspective of an alternative to figure 10 indicating use of the side-face of the outer storage rack for sequencing purposes;

[0066] Fig. 16 shows a schematic perspective of an alternative to figure 2 indicating use of the side-face of the outer storage rack for sequencing purposes;

[0067] Fig. 17 shows a schematic perspective of an alternative to figure 3 indicating use of the side-face of the outer storage rack for sequencing purposes;

[0068] Fig. 18 shows a schematic perspective of an alternative to figure 16 indicating use of the side-face of the outer storage rack for sequencing purposes.

[0069] In the figure 1 , 1 denotes as a whole a goods storage and order fulfillment system without a fixed conveyor system, meaning that no fixed conveyor system is used to connect the rack storage system 2 with an order fulfilment zone 3 having picking stations 4.

[0070] The system uses containers C for storage and transport of goods.

[0071] The rack storage system 2 and the order fulfilment zone 3 or the picking stations 4 are serviced by autonomous transport units 5. These autonomous transport units 5 retrieving or transferring containers C from or to the rack storage system 2 in order to transport containers to and from a certain picking station 4. The rack storage system 2 may in principle be of any known kind that allows storage and retrieval of containers.

[0072] The autonomous transport unit 5 is designed as a floor-bound conveying means with its own travel drive and which is automatically controlled and guided in a contactless manner. In other words, it is an AGV or AMR.

[0073] As generally shown in figure 1 , the area between the rack storage system 2 and the picking stations 4 does not use fixed classical conveyors to connect the different functional zones but makes use of the autonomous transport units 5.

[0074] The autonomous transport units 5 will interface with both the rack storage system 2 and the picking stations 4 to interchange the containers C with each other.

[0075] The rack storage system 2 has storage locations for goods containers C and uses at least one automated storage and retrieval machine for storing and retrieving containers into and from the storage locations of the rack storage system.

[0076] The autonomous transport units 5 carry a mobile shelf unit 6 with shelves 7 arranged vertically one above the other for at least one container C for the simultaneous transport of a plurality of containers C.

[0077] The picking stations 4 are supplied by the autonomous transport units 5 by means of the mobile shelf unit 6 with containers C for at least partial order fulfillment on the basis of order data. The system and the order fulfillment are controlled by an overall controller 8. Different variations of the system will be described with reference to the figures below.

[0078] Like parts will be referenced with same reference numbers.

[0079] Figures 2 and 4 - 12 show a schematic perspective view of a goods storage and order fulfillment system 1 without a fixed conveyor system and with a lift-free storage system 20, in more detail.

[0080] The lift-free storage system 20 is a double deep rack storage for containers C with aisles 21 between adjacent back-to-back multilevel racks 22. Single level rack servicing machines 23 of the shuttle type drive along tracks in each level of the racks 22. The tracks 22A are arranged on the front of the racks 22 in the longitude of the aisles 21. The shuttles 23 have a carrying area 23A for a container C and load handling means for sideways retrieval and discharge of containers to each side of the aisle 21 in the form of telescopic arms 23B on both sides of the carrying area having multiple fingers 23C for selectively engaging the containers to push form the carrying area or pull them onto it.

[0081] The shuttles 23 in this embodiment are also constructed to allow the shuttle to change levels by climbing (see figure 7).

[0082] The climbing means of each shuttle 23 includes a set of four climbing wheels 24 for interaction with the vertical climbing rails 25, the four climbing wheels 24 having a perpendicular axis of movement in comparison to the four travelling wheels (for moving along the tracks 22A) and the four climbing wheels 24 being retractable between an extended engaging position for interaction with the vertical climbing rails 25 and a retracted non-engaging position while travelling horizontally along the running tracks 22A horizontally along the respective storage rack level.

[0083] Additionally, it is possible to implement cross aisle running rails to form a bridge perpendicular to aisle direction for movement of each shuttle between aisles, preferably propelled by the set of the four climbing wheels. Then it is even possible for the storage and retrieval apparatus to change aisles without leaving the racking.

[0084] Additionally, the rack storage may have inter-aisle exchange positions for allowing the shuttles 23 to push / pull containers from one aisle 21 to an adjacent aisle 21 , as known from EP 2 741 977 B1.

[0085] In an embodiment the gear wheels (pinion) may be implemented as self-locking (e. g. by self-weight of the storage and retrieval apparatus) so as to stop a storage and retrieval apparatus in the event of (a power) failure from uncontrolled vertical travel or crash. To do so the gear wheels may be attached by pivoting arms to the frame of the storage and retrieval apparatus such that it implements a wedge-like function. Additionally, the gear wheels may be equipped with a mechanical failsafe brake, which would hold a storage and retrieval apparatus in a current position even if power or control is lost as long as pinions are locked.

[0086] The autonomous transport units 5 are of the AMR type and as such are able to navigate dynamically as well as plan its own path. They are equipped with on board devices to understand and react to the operating environment. This gives it a high flexibility in multiple order fulfillment use applications.

[0087] The autonomous transport unit 5 and the mobile shelf unit 6 may be permanently fixed together or separably connected.

[0088] If they are separate the autonomous transport units 5 comprise a lifting platform 5a (see figures 7-9) for engaging a mobile shelf 6 from below for lifting it off the ground and supporting it during transportation. The lifting platform 5a may be mechanically, pneumatically or hydraulically driven.

[0089] The lifting platform 5a of the autonomous transport unit 5 contains a rotatable unit 5b to change the orientation of a supported mobile shelf 6. It is also be tiltable under the control of a controller 5c of the autonomous transport unit 5 to counter shelf movement during transport based on sensor 5d input.

[0090] In the fixed version, the vertically stacked shelves 7 of the mobile shelf 6 have actively driven conveying means 7a in figures 2-6 and a load handling mean 6a for containers C.

[0091] Alternatively, the vertically stacked shelves 7 of the mobile shelf 6 are passive, as in figures 7-9.

[0092] For exchange of the containers C at the lift-free storage system 20 there are several possibilities.

[0093] In one possibility, shown in figures 7 - 9 and 11 the vertically stacked shelves 7 of the mobile shelf 6 are loaded and unloaded by the shuttles 23 of the lift-free storage system 20 itself using its load handling means 23B, C.

[0094] As shown in figures 7 - 9 and 11, a further different possibility is for the autonomous transport unit 5 to exchange the whole separate mobile shelf 6 in the racks 22. The mobile shelf 6 would then be positioned by the autonomous transport unit 5 within the racks 22 footprint such that is can be serviced by the shuttle 23.

[0095] The frontal part of the racks 22 have an empty space 22B corresponding to size of the autonomous transport unit 5 together with the mobile shelf 6 and the autonomous transport unit carrying the mobile shelf unit may therefore enter a rack from the front side and deposit the mobile shelf 6 (see figure 7, 11).

[0096] As shown in figures 4 and 5, a different possibility is for the autonomous transport unit 5 to use its own load handling means 6a to grip the containers C at the short side (figure 4) or long side (figure 5) in the racks 22. The autonomous transport unit 5 would then drive into an aisle 21 and actively exchange containers on racks 22, preferably at the beginning of the aisle. Alternatively, see figure 6, the autonomous transport unit 5 may approach the storage rack 22 from the front (not entering the aisle) for accessing rack conveyors 22C arranged in the frontal part of the racks 22 on lower levels for drop-off or pick-up of containers C from or to a mobile shelf being carried.

[0097] In general, the levels of the shelves 7 of the mobile shelf 6 coincide with the storage levels of the racks 22.

[0098] Figure 3 shows a schematic perspective view of a goods storage and order fulfillment system 10 without a fixed conveyor system but with a variant storage 200 having a dedicated lift 201 for each rack 222, in more detail. In general, the vertically stacked shelves 7 of the mobile shelf 6 may be loaded and unloaded by rack conveyors 22C arranged in the frontal part of the racks. Such conveyors would be integrated into the footprint of a rack 22 on lower levels and allow the automated storage and retrieval machine 23 to drop-off or pick-up containers C for decoupling.

[0099] It is also possible to use autonomous transport units 5* (see figure 12) that only carry a single container C and not a mobile shelf 6.

[0100] In figures 1, 2, 3 and 8 the picking station 4 uses a loading and unloading unit 40 for loading and unloading the mobile shelf 6. In these variants the containers C are unloaded from and loaded onto mobile shelf 6 in the loading and unloading unit 40, which is associated with the respective picking stations 4.

[0101] Such loading and unloading units 40 (see figure 13 and 14) displace the containers C from the mobile shelves 6 by push-pull mechanisms 41 on each shelf level 42 and use an integrated lift 43 to drop-off and pickup containers C to a conveyor 44 servicing the pick location 45. Such loading and unloading units 40 are arranged side-by-side. One unit 40a is used for unloading and the other unit 40b is used for loading of the mobile shelves 6.

[0102] One conveyor 44a is serviced from the loading and unloading unit 40a and the other one 44b feeds back into the loading and unloading unit 40b. The conveyors 44a, b will form a loop which in turn form a picking location 45 for the human operator (picker) or robotic picking device.

[0103] As shown in figures 13A, B the loading and unloading unit 40 itself can also be stationary (figure 13A) or the loading and unloading unit 40* can be configured to mobile (figure 13B) using drive means and wheels 46*.

[0104] As shown in figures 14A, B the mobile shelf 6, in the separate version (see figure 14A) or and in the fixed version (see figure 14B), can be unloaded using the push-pull mechanisms 41 on each shelf level 42 and use the integrated lift 43 to drop-off and pickup containers C to a conveyor 44 servicing the pick location 45. Alternatively, as shown in figures 9 and 10, the picking station 400 may be “virtually” formed by arranging mobile shelves 6 with source containers Cs and mobile shelves 6 with order containers Co such that they are both accessible for the human operator O (picker) at a picking location 445. This can be the case with either separate mobile shelves (figure 9) or fixed mobile shelves (figure 10).

[0105] The autonomous transport units 5 can also be used to transport finished order containers Co from a loading and unloading unit 40 to other areas of the order fulfillment system, e. g. packing and shipping.

[0106] As indicated in figures 15 - 18, the face X of the storage system, i. e. the outer side of the outer most rack 22 may be used as a sequencing front zone and / or temporary buffer for the autonomous transport units 5. Containers C are transferred, under the control of the controller, to the face X by shuttles 23. This may also take place across multiple aisles 21. Such a transfer of containers C can be performed by the shuttles 23 having the ability to change aisles, i. e. by the use of cross-aisle roaming, or by the shuttles 23 performing inter-aisle transfer (as described above and indicated by the hashed arrow).

[0107] It is possible to use both outer sides of the outer most racks 22 on both sides of a storage.

[0108] The containers C can then e. g. be pushed from the shuttles 23 to a double deep storage position, i. e. they are positioned at the outside storage locations of the outer most rack 22, where they can be accessed by the autonomous transport units being AMR 5.

[0109] This alternative embodiment could be used for slower systems or for secondary flow operations. For example, if the front of the storage is dedicated to picking at workstations, the replenishment / decanting could flow through the sides of the storage.

[0110] Such embodiments may be implemented with various versions of the storage system and order fulfillment system.

[0111] As indicated in figure 16, the vertical climbing rails 25, positioned at the ends of the racks 22 or aisles 21, may be used as directional paths. One climbing rail 25A would be an upwards track and one climbing rail 25B at the other end would be used as a down ward path.

[0112] In figure 17 the storage 200 is a normal shuttle storage as in figure 3, but with the advantage of using the face X of the storage system, i. e. the outer side of the outer most rack 222 may be used as a sequencing front zone and / or temporary buffer for the autonomous transport units 5.

[0113] According to figure 18, in which a variant of figure 16 is shown, the concept of using the face X of the storage system, i. e. the outer side of the outer most rack 2022 may be used as a sequencing front zone and / or temporary buffer for the autonomous transport units 5, can be combined with systems having conventional front zones and picking stations 400 connected to the storage 2000 via conveyors 500 as described in WO 2021 / 223881 A1.

[0114] This allows the replenishment and / or decanting to be performed by the AMR 5 using the face X on the sides of the storage. This alleviates traffic in the front of the storage and provides a means to decouple the picking and decanting operations.

[0115] The AMR 5 can then be used to supply the conventional picking stations 400 in parallel to the conveyors 500. In this sense, the side face X of the outer rack 2022 is used as an additional front zone.

Claims

Claims1. Goods storage and order fulfillment system without a fixed conveyor system- with a rack storage system having storage locations for goods containers;- with at least one automated storage and retrieval machine of the rack storage system for storing and retrieving containers into and from the storage locations of the rack storage system;- with at least one autonomous transport unit for retrieving or transferring of containers from or to the storage and retrieval machine in order to transport containers to and from a picking station, wherein the autonomous transport unit is designed as a floorbound conveying means with its own travel drive and which is automatically controlled and guided in a contactless manner;- the autonomous transport unit having a mobile shelf unit with shelves arranged vertically one above the other for at least one container for the simultaneous transport of a plurality of containers;- and with at least one picking station which is supplied by the autonomous transport unit by means of the mobile shelf unit with containers for at least partial order fulfillment on the basis of order data.

2. Goods storage and order fulfillment system according to claim 1 , characterized in that the autonomous transport unit and the mobile shelf unit are permanently fixed together.

3. Goods storage and order fulfillment system according to claim 1, characterized in that the autonomous transport unit and the mobile shelf unit are separably connected.

4. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the picking station uses a loading and unloading unit for loading and unloading the mobile shelf unit.

5. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the vertically stacked shelves of the mobile shelf have actively driven conveying means and optionally a load handling means for containers.

6. Goods storage and order fulfillment system according to any proceeding claim 1 - 4, characterized in that the vertically stacked shelves of the mobile shelf are passive.

7. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the vertically stacked shelves of the mobile shelf are loaded and unloaded by the automated storage and retrieval machine of the rack storage.

8. Goods storage and order fulfillment system according to claim 7, characterized in that the frontal part of the racks have an empty space corresponding to the size of the autonomous transport unit together with the mobile shelf unit and the autonomous transport unit carrying the mobile shelf unit can enter a rack from the front side and optionally deposit the mobile shelf.

9. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the vertically stacked shelves of the mobile shelf are loaded and unloaded by rack conveyors arranged in the frontal part of the racks.

10. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the height of the mobile shelf unit coincides with the height of the racks and the shelves are on the same level as the storage locations.

11. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the rack storage system is a shuttle storage having multi-level racks, that share an aisle between them and shuttles travel the length of the aisle as single level handling automated storage and retrieval machines.

12. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the rack storage system is a container-lift-free shuttle storage having multi-level racks, that share an aisle between them and shuttles travel the length of the aisle as single level handling automated storage and retrieval machines, and is implemented to travel vertically between to uprights.

13. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the rack storage system comprises a grid of uprights in whichcontainers are stored besides and above each other and are to be retrieved and stored from above by robotic storage and retrieval carts, that travel on the top of the grid.

14. Goods storage and order fulfillment system according to claim 13, characterized in that the rack storage system includes a loading and unloading station for the mobile shelves serviced by the robotic storage and retrieval carts.

15. Goods storage and order fulfillment system according to any proceeding claim, characterized in that the outer side of the outer most rack is controlled to be used as a sequencing front zone and / or temporary buffer for the autonomous transport units.

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