Order fulfillment and storage system for goods

Abstract

Order fulfillment and storage system for goods, comprising subsystems for providing functions of the order fulfilment and storage system, the functions being chosen from the group consisting of a goods receiving unit for receiving goods, a goods storage unit for long-term storage of goods, a buffer storage unit for short-term storage of goods, a goods sorting unit for sorting goods, a picking unit for compiling goods into orders, an order sorting unit for sorting orders, an output unit for dispatching orders, and transport units for transporting the goods between the aforementioned units, wherein the order fulfilment and storage system has a higher-level controller implemented to control the cooperation between the subsystems, the subsystems each have a functional controller for controlling the subsystems overall functions and each also have hardware-related controllers for controlling their related hardware systems, wherein the higher-level controller communicates with the functional controllers via a first interface standard and the functional controllers communicate with the hardware-related controllers via a second interface standard, corresponding computer implemented method and computer program.

Description

[0001] Order fulfillment and storage system for goods

[0002] The invention relates to an order fulfillment and storage system for goods, comprising a goods receiving unit for receiving goods, a goods storage unit for long-term storage of goods and supplying a buffer storage unit, a buffer storage unit for short-term storage of goods and supplying a picking unit, a sorting unit for goods, a picking unit for compiling goods into orders, a sorting unit for orders, an output unit for dispatching orders, and transport units for transporting the goods between the aforementioned units according to claim 1 and corresponding computer implemented method and computer program.

[0003] In the case of warehouses within the field of internal logistics or supply and distribution centers etc., it is generally known to control and regulate the material flow of items on the conveyance techniques through the use of local sensors and local decentralized controls (PLCs) which recognize or determine the items and their position.

[0004] For instance, in order to actuate drives in such conveyance techniques (actuators) the position of the goods being conveyed (items) must be reliably determined. This takes place typically with the aid of light barriers and light scanners (sensors).

[0005] To a limited extent, the position of the goods being conveyed is also calculated using known conveyance times since the last position status message (e.g. tracking).

[0006] The goods being conveyed are identified mostly by reading barcodes or other markings (scanners).

[0007] EP 3 009 984 A1 describes the optical recognition of optical codes by means of image recognition of the codes and comparison of movement vectors.

[0008] Movements of the material flow equipment or conveyance techniques are triggered on the basis of status messages from the sensors mostly in a decentralized manner via control computers, so-called programmable logic controllers (PLCs).

[0009] Therefore, this requires a considerable amount of outlay. The outlay for actuating the actuators includes sensors including their cabling for the supply of current, the data connection of all sensors and conveyor actuators, such as e.g. driven stoppers, switches, pushers etc. with the control computer(s) (PLCs) as well as the creation of the program code for the PLCs. The corresponding costs for material, installation, commissioning and programming as well as maintenance constitute a considerable portion of the total costs of the installation, wherein the control system generally costs more than the mechanical system. The availability of staff who have specialist knowledge of PLC programming is an additional requirement.

[0010] In US 2014 / 0236555 A1 it is disclosed to allow real data from a logistics installation to be incorporated into a virtual model thereof in order to improve or render more realistic the virtual environment in terms of the conveying flow so as to obtain improved test results.

[0011] Furthermore, the article “Decentralized Control of a Material Flow System Enabled by an Embedded Computer Vision System” (Communications Workshops (ICC), 2011 IEEE International Conference on, 20110605 IEEE - ISBN 978-1-61284-954-6; ISBN 1-61284-954-7) discloses the use of camera-based object recognition by means of markers at the level of the decentralized controllers.

[0012] It is known from EP 2 183 175 B1 to control a conveyance technique in real time by means of optical sensors and also image sensors. However, in larger installations this involves considerable outlay for real-time processing and evaluation of the image data, in particular image recognition.

[0013] Therefore, it is the object of the invention to provide an improved order fulfillment and storage system that allows to implement improvements in the control of an area or function without influencing other areas or functions.

[0014] This object is achieved by the system presented in claim 1 and the corresponding computer implemented method of claim 9 and computer program of claim 10.

[0015] In accordance with the invention, it has been recognized that, if the order fulfilment and storage system has a higher-level controller implemented to control the cooperation between the subsystems, the subsystems each have a functional controller for controlling the subsystems overall functions and each also have hardware-related controllers for controlling their related hardware systems, wherein the higher-level controller communicates with the functional controllers via a first interface standard and the functional controllers communicate with the hardware- related controllers via a second interface standard, it becomes possible to use a hardware independent higher-level controller to communicate via a first generic interface in a modular fashion and to functionalize communication to the subsystems (units) so that these are independent from each other but still standardized.

[0016] This allows the system to be segmented into individual smaller modules (subsystems) which are easier to manage and can be evolved independently. The details of the subsystems are hidden by the use of the well-defined first generic interface. The interface standard may be standardized for each type of subsystem.

[0017] The higher-level controller orchestrates the cooperation between various subsystems to enable the material flow for the whole order fulfillment and storage system. The subsystems themselves need not be aware of each other. All synchronization and coordination between them are performed by or through the higher-level controller.

[0018] In an embodiment the first interface standard is operative to bidirectionally control the flow of goods between the subsystems and to bidirectionally control the flow of information between the higher-level controller and the subsystem functional controllers. Each subsystem may have inbound and outbound commands, which communicate with the higher-level controller.

[0019] In a further embodiment the higher-level controller and at least one of the functional controllers are each operative to control the flow of goods and the associated information flow bidirectionally via the first interface standard with regard to one of the following functions: goods receipt, goods storage, goods relocation, goods retrieval, goods sorting, goods labelling, picking, replenishment, order sorting, order packing, order dispatch, goods transport.

[0020] Accordingly, it is preferred that the higher-level controller and at least one of the functional controllers are each operative to bidirectionally communicate via the first interface standard using standardized functionally-independent commands. The commands may be independent of the subtype of the subsystems.

[0021] It is possible to additionally use functionally-specific commands. In a preferred embodiment, the higher-level controller is operative to coordinate the higher-level flow of goods and the associated flow of information between the subsystems for the overall system.

[0022] Such coordination between the subsystems for the overall system may take place by means of transfer points. At the transfer points goods leave one subsystem and are handed over (transferred) to a second subsystem. The goods arrival at the transfer point initiates the coordination process by the higher-level controller.

[0023] The higher-level controller may take care of order control, replenishment of goods, flow synchronization etc. Accordingly, the higher-level control system may be set up to control the replenishment of goods, value-added services and / or quality control for the overall system. The higher-level controller may aggregate data from the subsystems. The higher-level controller may be responsible for considering staging times, capacity constraints, transport times etc. and for optimization of order fulfilment.

[0024] The first interface standard may abstractly contain an instruction (command) or information, an indication of goods and respective number of goods, for exchange with a subsystem.

[0025] The second interface standard used within a subsystem may specifically contain an instruction or information, an indication of goods and respective number of goods to a hardware-related controller.

[0026] In this way, a hardware-related controller, may be seen as providing a standardized micro-service that can be reused as a building block within the specific type of subsystem.

[0027] A subsystem may also carry the implementation of the underlying hardware in the subsystem and be responsible for local optimization of the (sub)system.

[0028] The invention also relates to a computer-implemented method for controlling an order fulfillment and storage system for goods, comprising subsystems for providing functions of the order fulfilment and storage system, the functions being chosen from the group consisting of receiving goods, long-term storage of goods, for short-term storage of goods, sorting goods, compiling goods into orders, sorting orders, dispatching orders, and transport transporting the goods, characterized by controlling the cooperation between subsystems and the subsystems with a higher-level controller; each subsystem controlling related hardware systems with hardware- related controllers; each subsystem having a functional controller, wherein the higher- level controller communicates with the functional controllers via a first interface standard and the functional controllers communicating with the hardware-related controllers via a second interface standard.

[0029] The invention further relates to a computer program comprising instructions which, when the program is executed by a computer, cause the computer to carry out the above method.

[0030] Subsystems are defined as providing functions of the order fulfilment and storage system. Such functions being chosen from the group consisting of a goods receiving unit for receiving goods, a goods storage unit for long-term storage of goods, a buffer storage unit for short-term storage of goods, a goods sorting unit for sorting goods, a picking unit for compiling goods into orders, an order sorting unit for sorting orders, an output unit for dispatching orders, and transport units for transporting the goods between the aforementioned units.

[0031] A goods receiving unit for receiving goods may be any kind of means for receiving goods into the order fulfillment and storage system. It will usually comprise ramps, gates, staging areas and functional areas (e.g. for checks and load securing). The organization and scope of goods receiving unit are relevant to the performance of a warehouse. If goods receiving unit is incorrectly planned or poorly organized, this can lead to disruptions in operations. In the goods receiving unit, goods are identified and first checked visually for completeness and damage. Goods are then recorded and relabeled if necessary. Goods may also be segmented or grouped into units for use in the warehouse or system. After a successful incoming goods inspection, the goods are booked and forwarded for transportation to a e. g. goods storage unit.

[0032] A goods storage unit for long-term storage of goods may be any kind of means for longer storage of goods. Usually this will be pallet storages in the form of high-bay racks, shuttle-operated container storages, ASRS operated container storages or of the AutoStore type. They may be manually, automated or fully automatic in operation. They will be supplied from a goods receiving unit by transportation units and e. g. supply a buffer storage unit for short-term storage of goods or a picking unit for compiling goods into orders.

[0033] A buffer storage unit for short-term storage of goods may be any kind of means for shorter storage of goods, i. e. having faster access and supply on demand rates than the goods storage unit for long-term storage. Usually this will be shuttle-operated container storages, ASRS operated container storages or of the AutoStore type. They may be automated or fully automatic in operation. They will be supplied (restocked or replenished) from a goods storage unit for long-term storage by transportation units and e. g. supply a picking unit for compiling goods into orders.

[0034] A goods sorting unit for sorting goods may be any kind of means for sorting goods based on source, type or destination. Such may be of the linear or circular type, rotary sorters, tilt switch sorters, and drop flap sorters. The circular sorter and linear sorter are special conveyor systems. With a sorter system, sorted goods are separated by order and distributed to a certain number of target stations. Whether a linear sorter or a circular sorter is suitable depends on two components: The storage option and the network structure. The network structure is the relationship between the locations of the stations, the connecting routes and their networking. Circular sorters, like sorting carousels, are dynamic circulating storage systems. A distinction is made between designs with and without an intermediate buffer. Further, the mentioned shuttle- operated container storages may be operated as sorting units or be used to sort goods when these are discharged.

[0035] A picking unit for compiling goods into orders may be any kind of manually operated and / or robotically operated station or system for combining goods according to order lists into specific orders for later dispatch. Usually these will be goods-to-person (or robot) stations, in which the station is supplied with the goods by transportation units and also the discharge is organized by transportation units. Alternatively, these may be person-to-goods (or robot) stations, in which the operator or robot travels to the goods in storage and then discharges or unloads the picked to transportation units.

[0036] An order sorting unit for sorting orders may be any kind of means for sorting orders based on source, type or destination. Such may be of the linear or circular type, rotary sorters, tilt switch sorters, and drop flap sorters. The circular sorter and linear sorter are special conveyor systems. With a sorter system, sorted order are e. g. separated by destination and distributed to a certain number of dispatch units. Further, the mentioned shuttle-operated container storages may be operated as sorting units or be used to sort goods when these are discharged.

[0037] An output unit for dispatching orders may be any kind of means for dispatching (shipping) goods from the order fulfillment and storage system. It will usually comprise ramps, gates, staging areas and functional areas (e.g. for checks and load securing). The organization and scope of output unit for dispatching orders are relevant to the performance of a warehouse. If output unit for dispatching orders is incorrectly planned or poorly organized, this can lead to disruptions in shipping operations. In the output unit for dispatching orders, orders are identified and first checked visually for completeness and damage. Orders are then recorded, packed and relabeled if necessary. Orders may also be segmented or grouped into logistic units for transportation to the destinations.

[0038] A transport unit for transporting the goods between the aforementioned units may be any king of transportation means. Usually these will be conveyors (of any type, like roller or belt conveyors), forklifts, AGV or AMR. It is also possible to use the sorting units for certain transportation functions between subsystems.

[0039] The system may include a reporting and analytics unit as a “virtual” subsystem. This subsystem provides tools for generating reports and analyzing warehouse performance metrics. It includes functionalities such as real-time dashboards, key performance indicators (KPIs) tracking, trend analysis, and forecasting. This subsystem helps warehouse managers make informed decisions and continuously improve warehouse operations.

[0040] The high-level controller and the subsystem functional controllers may be implemented in a software application that helps manage and control warehouse operations, including inventory management, order fulfillment, receiving, picking, packing, and shipping. The implementation of the high-level controller can occur in various contexts depending on the needs and requirements of the organization. Here are some common contexts in which high-level controller may be implemented: Retail and e-commerce: In retail and e-commerce, where there's a high volume of orders and inventory turnover, implementing a high-level controller becomes crucial for efficient order processing, inventory accuracy, and timely fulfillment.

[0041] Manufacturing: Manufacturers may use high-level controller to manage raw materials, work-in-progress inventory, and finished goods within their warehouses or distribution centers. This ensures smooth production processes and optimal inventory levels.

[0042] Distribution and Logistics: Companies involved in distribution and logistics may rely on a high-level controller to streamline their operations, improve inventory visibility, and optimize the movement of goods within the supply chain.

[0043] Third-Party Logistics (3PL): Third-party logistics providers manage warehousing and distribution on behalf of multiple clients. Implementing a high-level controller may help them efficiently handle diverse inventory requirements and meet the specific needs of each client.

[0044] Wholesale and Distribution Centers: Wholesalers and distribution centers benefit from a high-level controller to manage large-scale inventories, handle complex order requirements, and optimize warehouse space utilization.

[0045] As for the deployment options, a high-level controller can be implemented either onpremise or in the cloud or in hybrid scenario:

[0046] In an on-premise deployment, the high-level controller software is installed and maintained on the organization's own servers and IT infrastructure within its physical premises. This option provides a high level of control and customization but requires significant upfront investment in hardware, software licenses, and IT resources for maintenance and upgrades.

[0047] With cloud-based deployment, the high-level controller software is hosted and managed by a third-party service provider on remote servers accessible via the internet. This option typically offers lower upfront costs, scalability, and easier access to updates and new features. It also reduces the burden on internal IT teams as maintenance and upgrades are managed by the service provider. Additionally, cloudbased WMS solutions are often more flexible and adaptable to changing business needs.

[0048] Ultimately, the choice between on-premise and cloud-based deployment depends on factors such as budget, IT infrastructure, scalability requirements, security considerations, and the organization's overall IT strategy.

[0049] In some cases, the high-level controller and the subsystem functional controllers may be implemented on a component such as a microprocessor, a computer processing unit, a silicon-on-chip, a graphene-on-chip, a neural network-on-chip, a neuromorphic chip (NeuRRAM), a system on chip (SoC), a system-in-package (SIP) configuration, or any suitable configuration configured to manage and control one or more of the warehouse operations.

[0050] The invention emphasizes breaking down a program into smaller, independent modules or components, each responsible for specific functions or features. This approach offers several advantages in the context of implementing an order fulfillment and storage system for goods according to the invention, regardless of whether it's deployed on-premise or in the cloud.

[0051] Modularizing facilitates scalability by allowing developers to add or remove modules as needed without affecting the entire system. In the context of the invention, this means that as warehouse operations grow or evolve, new functionalities can be seamlessly integrated into the system without disrupting existing processes.

[0052] With Modularizing, each subsystem and its components can be developed and customized independently, making it easier to tailor the system to specific business requirements. Organizations can choose modules that best suit their needs and easily modify or extend them as needed, whether it's adding support for new warehouse processes or integrating with other enterprise systems.

[0053] Modularizing promotes code reusability and maintainability. Each module can be maintained and updated independently, reducing the risk of unintended side effects on other parts of the system. This simplifies maintenance tasks such as bug fixes, performance optimizations, and security updates, making the high-level controller and also the subsystems more robust and reliable over time. In another embodiment, one or more of the modules, subsystems, and components may further be partitioned or broken down into one of services, sub-services, processes, sub processes, or a combination thereof as needed for the modules or components to provide modules as a service (MaaS) or subsystems as a service (SaaS).

[0054] By designing the high-level controller and also the subsystems as a collection of loosely-coupled modules, organizations can improve interoperability with other systems and technologies. For example, modules responsible for inventory management, order processing, and shipping can be designed to communicate seamlessly with external systems such as ERP software, transportation management systems, or e-commerce platforms via the higher-level controller.

[0055] Modularizing facilitates unit testing and debugging, as developers can isolate and test each subsystem and hardware system independently. This helps to identify and resolve issues more efficiently, leading to higher software quality and faster development cycles.

[0056] Whether deploying the higher-level controller on-premise or in the cloud, modular programming allows organizations to adapt the system architecture to their chosen deployment model. For instance, cloud-based solutions may leverage microservices architecture, where each subsystem may correspond to a self-contained service running on cloud infrastructure.

[0057] In one embodiment, a microservice is a building block or component of a software architecture that divides a program or application into components based upon the services those individual components (microservices) provide or perform. Each individual service within an exemplary microservice would be developed and maintained as a separate and discrete piece of software. Such arrangement allows a microservice (and its services) to be considered a “plug-n-play” component of a larger application or program such as order fulfillment and storage system.

[0058] In summary, the invention offers numerous benefits for implementing an order fulfillment and storage system for goods, including scalability, flexibility, maintainability, interoperability, and adaptability to different deployment models. By breaking down the control into modular components, it is possible to build a more agile, customizable, and efficient system.

[0059] Further features and details of the invention will be apparent from the following description of the drawing. In the drawing:

[0060] Figure 1 shows a block diagram of the control architecture of an order fulfilment and storage system with a higher-level controller implemented to control the cooperation between a subsystem example being a storage unit, the subsystem having a functional controller for controlling the subsystem’s overall functions and also having hardware-related controllers for controlling the related hardware systems;

[0061] Figure 2 shows a flow diagram of an order fulfilment and storage system with subsystems; and

[0062] Figure 3 shows a shuttle storage and picking subsystem of figure 2 in an abstract block diagram view (A) and a corresponding low level mechanical view (B).

[0063] Figure 1 depicts a block diagram of the control architecture of an order fulfilment and storage system 100 with a higher-level controller 10 implemented to control the cooperation between a subsystem 20 being a storage unit, the subsystem having a functional controller 30 for controlling the subsystem’s overall functions and also having hardware-related controllers 41 , 42, 43, 4X for controlling the related hardware systems.

[0064] The higher-level controller 10 communicates with the functional controller 30 of the storage unit 20 via a first interface standard 15 and the functional controller 30 communicates with the hardware-related controllers 41 for ASRS control, 42 for lift control, 43 for conveyor control, 4X for further function via a second interface standard 35.

[0065] The first interface standard 15 is operative to bidirectionally control the flow of goods between the subsystems and to bidirectionally control the flow of information between the higher-level controller 10 and the subsystem functional controller 30.

[0066] The higher-level controller 10 and the functional controller 30 are each operative to control the flow of goods and the associated information flow bidirectionally via the first interface standard 15 with regard to goods storage, as the subsystem is a storage unit, using standardized functionally-independent commands.

[0067] Such commands used in the first interface standard 15 abstractly contain an instruction or information, an indication of goods and respective number of goods. For example, a command could be “store item #1234, 10 pieces” or “retrieve item #4321, 5 pieces”. Such command could be initiated or communicated when the respective goods arrive at a transfer point, for example on a conveyor connecting a receiving unit with the storage unit.

[0068] The higher-level controller 10 is operative to coordinate the higher-level flow of goods and the associated flow of information between the storage unit 20 and further subsystems (not shown) for the overall system 100 using transfer points.

[0069] Order fulfilment and storage system 100 may also use the higher-level controller 10 to control the replenishment of goods, track and control value-added services and / or quality control for the overall system, for example by creating and tracking KPI’s.

[0070] In figure 2 the interaction and flow of goods between subsystems in the order fulfillment and storage system 100* is shown. The overall control and information exchange is again performed by higher-level controller 10* interfacing via bidirectional first interface 15* with the subsystems.

[0071] The subsystems provide the functions of the order fulfilment and storage system 100*. The functions being:

[0072] - A goods receiving unit 1* for receiving goods, for example via truck from suppliers, manufacturer etc. Usually, this unit will contain comprise ramps, gates, staging areas and functional areas (e.g. for checks and load securing). In the goods receiving unit 1*, goods are identified and first checked visually for completeness and damage. Goods are then recorded and relabeled if necessary. Goods may then also be segmented or grouped into units for use in the warehouse or system. After a successful incoming goods inspection, the goods are booked and forwarded for transportation to a e. g. goods storage unit 2*. The transportation unit 9* used between the goods receiving unit 1* and the goods storage unit 2* may be a conveyor or, if the pallets are directly stored, a forklift truck. The received goods on pallets are then transported to the outgoing-transfer point of the receiving unit 1* where point the transport unit 9* will take over the pallets and transport them to the destinations as exchanged with the higher-level controller 10*, i. e. goods storage unit 2* and its ingoing-transfer point.

[0073] - A goods storage unit 2* for long-term storage of goods of the highbay type for direct storage of pallets with goods from the receiving unit 1*. The goods storage unit 2* has its own control of storage optimization and control of hardware for storage and retrieval (ASRS) of goods etc. It also contains a depalletization process and area with respective hardware to supply goods to perform replenishment of units 3*, 4* and 5* (see below). These functions and hardware are controlled by the hardware related controllers and interface with the subsystem functional controller using the second interface. For example, when the higher-level controller 10* communicates to the functional controller of the goods storage unit 2* a command to "retrieve item #4321 , 5 pieces”, the functional controller will via the second interface direct the ASRS controller to retrieve the corresponding pallet from the high-bay storage rack and transport it to the depalletization area for depalletization under control of the depalletization controller for providing “5 pieces of item #4321” at the outgoingtransfer point of goods storage unit 2*. At the outgoing-transfer point the transport unit 9* will take over the “5 pieces of item #4321” and transport them to the destinations as exchanged with the higher-level controller 10* and the functional controller of the transport unit 9*. Therefore, the goods storage unit 2* only need to perform the discharge and supply to the transfer point. It does not need further information etc. to perform the task.

[0074] - A goods storage unit 3* for performing mid-term storage of goods and picking of the autostore type for storage of goods in containers. Again, the goods storage unit 3* has its own control of storage optimization and control of hardware for storage and retrieval (autostore bots etc.) of containers containing goods etc. It also contains a picking process and area with respective hardware to supply partial orders to unit 4* (see below). These functions and hardware are controlled by the hardware related controllers and interface with the subsystem functional controller using the second interface. For example, when the higher-level controller 10* communicates to the functional controller of the goods storage unit 3* a command to "retrieve item #4321 , 2 pieces”, the functional controller will via the second interface direct the autostore bot controller to retrieve the corresponding container from the autostore matrix and transport it to the picking area for picking “2 pieces of item #4321” into a partial order container under control of the picking controller for providing “2 pieces of item #4321” at the outgoing-transfer point of goods storage unit 3*. At the outgoing-transfer point - after the higher-level controller 10* receives information the corresponding command was executed and that the goods have arrived - the transport unit 9* will take over the container with “2 pieces of item #4321” and transport them to the destinations as exchanged with the higher-level controller 10* and the functional controller of the transport unit 9*. Therefore, the goods storage unit 3* only need to perform the discharge and supply to the transfer point. It does not need further information etc. to perform the task.

[0075] - A buffer storage unit 4* for short-term storage of goods and picking of the shuttle container storage type with an integrated goods-to-person picking area connected aisle-wise to the storage racking and supplied via lifts and conveyors. Again, the buffer storage unit 4* has its own control of storage optimization and control of hardware for storage and retrieval (shuttles and lifts as well as conveyors etc.) of containers containing goods etc. It also contains a picking process and area - as indicated - with respective hardware to supply orders to units 6* or 7* (see below). These functions and hardware are controlled by the hardware related controllers and interface with the subsystem functional controller using the second interface. For example, when the higher- level controller 10* communicates to the functional controller of the buffer storage unit 4* a command to "retrieve item #4321 , 4 pieces” and "retrieve item #1234, 2 pieces” for “order #666”, the functional controller will via the second interface direct the shuttle controller, lift controller and conveyor controller to retrieve the corresponding containers from the shuttle storage racking and transport them to the picking area for picking an order container (containing item #4321 , 4 pieces and item #1234, 2 pieces) under control of the picking controller for providing a corresponding container at the outgoingtransfer point of buffer storage unit 4*. At the outgoing-transfer point the transport unit 9* will take over the container for “order 666” and transport it to the destinations as exchanged with the higher-level controller 10* and the functional controller of the transport unit 9*- after the higher-level controller 10* receives information the corresponding command was executed and that the goods have arrived. Therefore, the buffer storage unit 4* only need to perform the discharge, picking and supply to the transfer point. It does not need further information etc. to perform the task. If the order container is a fulfilled complete order, the transport unit 9* will transport it to the packaging unit 7*. On the other hand, if order container contains a partial order, the transport unit 9* will transport it to the order consolidation unit 6*.

[0076] - A picking unit 5* for parallel manually compiling and / or picking delicate or very small or valuable goods into orders. Again, the picking unit 5* has its own control of storage optimization and control of hardware for instructing and directing the pickers to the goods etc. It also contains besides the picking process and area - as indicated - a respective hardware to supply orders to units 6* or 7* (see below). These functions and hardware are controlled by the hardware related controllers and interface with the subsystem functional controller using the second interface. For example, when the higher-level controller 10* communicates to the functional controller of the picking unit 5* a command to "retrieve item #1111, 1 piece” and "retrieve item #2222, 2 pieces” for “order #444 and order 222”, the functional controller will via the second interface direct the picker (voice guided, visually guided etc.) to retrieve the corresponding goods and place them in separate order containers, one for order #444 and one for order #222 under control of the picking controller for providing a corresponding container at the outgoing-transfer point of picking unit 5* At the outgoing-transfer point - after the higher-level controller 10* receives information the corresponding command was executed and that the goods have arrived - the transport unit 9* will take over the container for “order 666” and transport it to the destinations as exchanged with the higher-level controller 10* and the functional controller of the transport unit 9*. Therefore, the picking unit 5* only need to perform the discharge, picking and supply to the transfer point. It does not need further information etc. to perform the task. If the order container is a fulfilled complete single order (order #444 for example), the transport unit 9* will transport it to the packaging unit 7*. On the other hand, if order container contains a partial order (order #222 for example), the transport unit 9* will transport it to the order consolidation unit 6*.

[0077] - An order sorting unit 6* for sorting orders and consolidating partial orders received via transport units 9* from outgoing-transfer points of buffer storage unit 4* and picking unit 5* 5*. Again, this subsystem has its own functional controller to sort and consolidate the order container to achieve complete fulfilled orders for forwarding to packaging unit 7* and doing so in a certain sorted order. Depending on the implementation, the order sorting unit 6* has its own control of sorting and consolidation and control of hardware for instructing and directing the pickers and / or devices for consolidation of order and the sortation thereof etc. It also contains besides the consolidation process and area - as indicated - a respective hardware to supply completed orders to 7* (see below). These functions and hardware are controlled by the hardware related controllers and interface with the subsystem functional controller using the second interface. For example, when the higher-level controller 10* communicates to the functional controller of the order sorting unit 6* a command to "consolidate item #2222, 2 pieces with item #1234 for order 222”, the functional controller will via the second interface direct respective containers including these goods to be conveyed to the GTP station where a picker is in turn instructed (voice guided, visually guided etc.) to retrieve the corresponding goods and place them in a joint order container, for order #222 under control of the consolidation controller, to then provide the corresponding container at the outgoing-transfer order sorting unit 6*. At the outgoing-transfer point - after the higher-level controller 10* receives information the corresponding command was executed and that the goods have arrived - the transport unit 9* will take over the container for “order #222” and transport it to the packaging unit 7*as exchanged with the higher-level controller 10* and the functional controller of the transport unit 9*. Therefore, the order sorting unit 6* only needs to perform the consolidation, sorting and supply to the transfer point. It does not need further information etc. to perform the task. - A packaging unit 7* for placing fulfilled orders into packages or boxes for later shipping at output unit 8*. Usually, such a unit will have packaging stations to which the order containers are transported and where these are them emptied and the respective goods are placed order-wise into shipping containers, boxes etc. These can be manually and / or automated stations and include put- walls. As before, the packaging unit 7* has its own functional control and control of hardware direction of goods etc. It contains a packaging process and area with respective hardware to supply goods and shipping containers etc. to perform packaging of orders. These functions and hardware are controlled by the hardware related controllers and interface with the subsystem functional controller using the second interface. For example, when the higher-level controller 10* communicates to the functional controller of packaging unit 7* a command to "pack order #222”, the functional controller will via the second interface direct the conveyor controller to retrieve the corresponding container and transport it to the packaging station for placement of the respective goods into a shipping container under control of the packaging controller for providing “packed order #222 at the outgoing-transfer point of packaging unit 7*. At the outgoing-transfer point the transport unit 9* will take over the shipping container containing order #222 and transport it to the output unit 8* as exchanged with the higher-level controller 10* and the functional controller of the transport unit 9*. Therefore, the packaging unit 7* only need to perform the packaging and supply to the transfer point. It does not need further information etc. to perform the task.

[0078] - An output unit 8* for dispatching or shipping orders, for example via truck to customers or wholesalers etc. Usually, this unit will contain comprise ramps, gates, staging areas and functional areas (e.g. for checks and load securing). In the output unit 8*, shipments are identified and first checked visually for completeness and damage. Shipments are then recorded and relabeled if necessary. Shipments may then also be segmented or grouped into logistical units for transportation. After a successful inspection the shipments are booked and dispatched for transportation. The information of the shipment leaving the system may then be communicated from the subsystems functional controller to the higher-level controller 10* that then may interface with shipment tracking systems etc. for notification of customers and also with WMS system for ordering goods for restocking and replenishment.

[0079] The transport units 9* for transporting the goods and containers and pallets between the aforementioned units may be conveyors, shuttles, forklifts, autostore bots. They may differ depending on the stretch that they are functioning in. The differing kinds of transport units 9* may have the same functional or differing functional controllers.

[0080] All the aforementioned workflows and processes may be monitored and the collected data used for KPI creation and analysis, for example of through put, delivery times etc.

[0081] It is obvious, that the mentioned hardware related controllers are adapted to control the respective hardware in relation to its drives, sensors, functional groups etc.

[0082] Figure 3 shows the buffer storage unit 4* of figure 2 in an abstract block diagram view (A) and a corresponding low level mechanical view (B). This exemplifies the different abstraction levels used in the order fulfillment and storage system 100* for goods.

[0083] The higher-level controller 10* will communicate with the buffer storage unit 4* functional controller 30* via first interface 15* on an abstract command and information level as discussed above.

[0084] The buffer storage unit 4* functional controller 30* will in turn communicate with the hardware-related controllers 41*, 42*, 43*, 44* ... 4X for controlling the related hardware systems of the buffer storage unit 4*.

[0085] The buffer storage unit 4* interfaces with transport unit 9* on the input side or ingoingtransfer point to receive replenishment from unit 3* or 2*. The buffer storage unit 4* also interfaces with transport unit 9* on the output side or outgoing-transfer point to send order containers to units 6* or 7*.

[0086] The buffer storage unit 4* therefore has on the abstract level an input 4*a, an output 4*b, a buffer storage 4*c and a picking area 4*d. These functions have hardware related functions and respective controllers 41 , 42*, 43*, 44*. The buffer storage unit 4* functional controller 30* therefore receives high-level instructions or commands from the higher-level controller 10*, which it then interprets and uses to control its own functions. These are then implemented or executed on a lower level by the hardware in the respective functions input 4*a, output 4*b, buffer storage 4*c and picking area 4*d by communication via the second interface with respective controllers of buffer storage 41*, lifts 42*, conveyors 43*, picking stations 44* etc. to control the hardware including conveyors, lifts, shuttles, drives, sensors, picking stations etc.

Claims

Claims1. Order fulfillment and storage system for goods, comprising subsystems for providing functions of the order fulfilment and storage system, the functions being chosen from the group consisting of a goods receiving unit for receiving goods, a goods storage unit for long-term storage of goods, a buffer storage unit for short-term storage of goods, a goods sorting unit for sorting goods, a picking unit for compiling goods into orders, an order sorting unit for sorting orders, an output unit for dispatching orders, and transport units for transporting the goods between the aforementioned units, characterized in that the order fulfilment and storage system has a higher-level controller implemented to control the cooperation between the subsystems, the subsystems each have a functional controller for controlling the subsystems overall functions and each also have hardware-related controllers for controlling their related hardware systems, wherein the higher-level controller communicates with the functional controllers via a first interface standard and the functional controllers communicate with the hardware-related controllers via a second interface standard.

2. Order fulfillment and storage system according to claim 1 , characterized in that the first interface standard is operative to bidirectionally control the flow of goods between the subsystems and to bidirectionally control the flow of information between the higher-level controller and the subsystem functional controllers.

3. Order fulfilment and storage system according to claim 1 or 2, characterized in that the higher-level controller and at least one of the functional controllers are each operative to control the flow of goods and the associated information flow bidirectionally via the first interface standard with regard to one of the following functions: goods receipt, goods storage, goods relocation, goods retrieval, goods sorting, goods labelling, picking, replenishment, order sorting, order packing, order dispatch, goods transport.

4. Order fulfilment and storage system according to claim 3, characterized in that the higher-level controller and at least one of the functional controllers are each operative to bidirectionally communicate via the first interface standard using standardized functionally-independent commands.

5. Order fulfilment and storage system according to claim 3 or 4, characterized in that the higher-level controller is operative to coordinate the higher-level flow of goods and the associated flow of information between the subsystems for the overall system.

6. Order fulfilment and storage system according to claim 3 or 4, characterized in that the higher-level controller is operative to coordinate the higher-level flow of goods and the associated flow of information between the subsystems for the overall system by means of transfer points.

7. Order fulfilment and storage system according to one of the preceding claims, characterized in that the higher-level control system is set up to control the replenishment of goods, value-added services and / or quality control for the overall system.

8. Order fulfilment and storage system according to one of the preceding claims, characterized in that the first interface standard abstractly contains an instruction or information, an indication of goods and respective number of goods.

9. A computer-implemented method for controlling an order fulfillment and storage system for goods, comprising subsystems for providing functions of the order fulfilment and storage system, the functions being chosen from the group consisting of receiving goods, long-term storage of goods, for short-term storage of goods, sorting goods, compiling goods into orders, sorting orders, dispatching orders, and transport transporting the goods, characterized by controlling the cooperation between subsystems and the subsystems with a higher-level controller; each subsystem controlling related hardware systems with hardware-related controllers; each subsystem having a functional controller, wherein the higher-level controller communicates with the functional controllers via a first interface standard and the functional controllers communicating with the hardware-related controllers via a second interface standard.

10. A computer program comprising instructions which, when the program is executed by a computer, cause the computer to carry out the method of claim 9.

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