Inventory handling station assembly

Abstract

A storage and retrieval system comprising a grid framework structure (42) and an inventory handling station (44). The grid framework structure (42) comprising i) a track system (52) for guiding the movement of one or more load handling devices on the grid framework structure, and ii) a supporting 5 framework structure(48) comprising a plurality of storage columns (50), each of the plurality of storage columns being arranged below the track system (52) and being arranged to accommodate a stack of storage containers (12), said supporting framework structure (48) comprising at least one port column (46) arranged below the track system (52) for dropping off and / or picking up a storage container. The inventory handling station (44) comprising i) a compartment (54) for accommodating a storage container, said compartment (54) being arranged below the at least one port column (46) and comprising a first opening (56) for receiving a storage container lowered down the at least one port column along a first axis and a second opening (58) for moving the storage container along a second axis, said second axis being substantially perpendicular to the first axis; and ii) a door (70) moveable between a first position in which the compartment is able to receive a storage container from the at least one port column through the first opening along the first axis and a second position in which the door is retracted into the at least one port column to form a barrier between the track system and the compartment such that a storage container is prevented from being lowered into the compartment through the first opening along the first axis; wherein a storage container is 20 accessible through the second opening when the door is in the second position and wherein the storage container is inaccessible via the second opening when the door is in the first position.

Description

[0001] Inventory Handling Station Assembly

[0002] Field of Invention

[0003] The present invention relates to the field of a storage and retrieval system for handling storage containers or bins stacked in a grid framework structure, more particularly to an inventory handling station assembly for picking or supplying one or more items or goods to or from the storage and retrieval system comprising the grid framework structure.

[0004] Background

[0005] Storage and retrieval systems comprising a three-dimensional storage grid structure, within which storage containers / bins are stacked on top of each other, are well known. PCT Publication No. WO2015 / 185628A (Ocado) describes a known storage and fulfilment system in which stacks of bins or containers are arranged within a grid framework structure. The bins or containers are accessed by load handling devices remotely operative on tracks located on the top of the grid framework structure. A system of this type is illustrated schematically in Figures 1 to 3 of the accompanying drawings.

[0006] As shown in Figures 1 and 2, stackable containers, known as bins or containers 10, are stacked on top of one another to form stacks 12. The stacks 12 are arranged in a grid framework structure 14 in a warehousing or manufacturing environment. The grid framework is made up of a plurality of storage columns or grid columns 15. Each grid in the grid framework structure has at least one grid column for storage of a stack of containers. Figure 1 is a schematic perspective view of the grid framework structure 14, and Figure 2 is a top-down view showing a stack 12 of bins 10 arranged within the framework structure 14. Each bin 10 typically holds a plurality of product items (not shown), and the product items within a bin 10 may be identical, or may be of different product types depending on the application.

[0007] The grid framework structure 14 comprises a plurality of upright members or upright columns 16 that support horizontal members 18, 20. A first set of parallel horizontal grid members 18 is arranged perpendicularly to a second set of parallel horizontal grid members 20 to form a plurality of horizontal grid structures supported by the upright members 16. The members 16, 18, 20 are typically manufactured from metal and typically welded or bolted together or a combination of both. The bins 10 are stacked between the members 16, 18, 20 of the grid framework structure 14, so that the grid framework structure 14 guards against horizontal movement of the stacks 12 of bins 10, and guides vertical movement of the bins 10.

[0008] The top level of the grid framework structure 14 includes rails 22 arranged in a grid pattern across the top of the stacks 12. Referring additionally to Figure 3, the rails 22 support a plurality of load handling devices 30. A first set 22a of parallel rails 22 guide movement of the robotic load handling devices 30 in a first direction (for example, an X-direction) across the top of the grid framework structure 14, and a second set 22b of parallel rails 22, arranged perpendicular to the first set 22a, guide movement of the load handling devices 30 in a second direction (for example, a Y-direction), perpendicular to the first direction. In this way, the rails 22 allow movement of the robotic load handling devices 30 laterally in two dimensions in the horizontal X-Y plane, so that a load handling device 30 can be moved into position above any of the stacks 12.

[0009] A known load handling device 30 shown in Figure 4 and 5 comprises a vehicle body 32 is described in PCT Patent Publication No. W02015 / 019055 (Ocado), hereby incorporated by reference, where each load handling device 30 only covers one grid space of the grid framework structure 14. Here, the load handling device 30 comprises a wheel assembly comprising a first set of wheels 34 consisting a pair of wheels on the front of the vehicle body 32 and a pair of wheels 34 on the back of the vehicle 32 for engaging with the first set of rails or tracks to guide movement of the device in a first direction and a second set of wheels 36 consisting of a pair of wheels 36 on each side of the vehicle 32 for engaging with the second set of rails or tracks to guide movement of the device in a second direction. Each of the set wheels are driven to enable movement of the vehicle in X and Y directions respectively along the rails. One or both sets of wheels can be moved vertically to lift each set of wheels clear of the respective rails, thereby allowing the vehicle to move in the desired direction.

[0010] The load handling device 30 is equipped with a lifting device or crane mechanism to lift a storage container from above. The crane mechanism comprises a winch, a tether or cable 38 wound on a spool or reel (not shown) and a grabber device 39. The lifting device or crane mechanism comprise a set of lifting tethers 38 extending in a vertical direction and connected nearby or at the four comers of a lifting frame 39, otherwise known as a grabber device (one tether near each of the four comers of the grabber device) for releasable connection to a storage container 10. The grabber device 39 is configured to releasably grip the top of a storage container 10 to lift it from a stack of containers in a storage system of the type shown in Figure 1 and 2.

[0011] The wheels 34, 36 are arranged around the periphery of a cavity or recess, known as a container-receiving recess 40, in the lower part of the load handling device. The recess is sized to accommodate the container 10 when it is lifted by the crane mechanism, as shown in Figure 5 (a and b). When in the recess, the container is lifted clear of the rails beneath, so that the vehicle or load handling device can move laterally to a different location. On reaching the target location, for example another stack, an access point in the storage system or a conveyor belt, the bin or container can be lowered from the container receiving portion and released from the grabber device.

[0012] Thus, upon receipt of a customer order, a load handling device operative to move on the tracks is instructed to pick up a storage bin containing the item of the order from a stack in the grid framework structure and transport the storage bin to a pick station whereupon the item can be retrieved from the storage bin. Typically, the load handling device transports the storage bin or container to a bin lift device that is integrated into the grid framework structure. A mechanism of the bin lift device lowers the storage bin or container to a pick station. At the pick station, the item is retrieved from the storage bin. Picking can done manually by hand or by a robot as taught in GB2524383 (Ocado Innovation Limited). After retrieval from the storage bin, the storage bin is transported to a second bin lift device whereupon it is lifted to grid level to be retrieved by a load handling device and transported back into its location within the grid framework structure. A control system and a communication system keeps track of the location of the storage bins and their contents within the grid framework structure. As individual containers are stacked in vertical layers, their locations in the grid framework structure or “hive” may be indicated using co-ordinates in three dimensions to represent the load handling device or a container’s position and a container depth (e.g. container at (X, Y, Z), depth W). Equally, locations in the grid framework structure may be indicated in two dimensions to represent the load handling device or a container’s position and a container depth (e.g. container depth (e.g. container at (X, Y), depth Z). For example, Z=1 identifies the uppermost layer of the grid, i.e. the layer immediately below the rail system, Z=2 is the second layer below the rail system and so on to the lowermost, bottom layer of the grid.

[0013] Equally when stocking the storage system with items or replenishing the inventory of the storage system, items delivered from a supplier is transported to a decant station or a supply station. Here, the items are removed from their packaging and depending on the type of item, registered with a unique stock keeping unit or SKU, and placed in storage bins at the decant station. At the decant station, the storage bins are transported to a bin lift device whereupon it is lifted to grid level to be retrieved by a load handling device and transported to a location within the grid framework structure.

[0014] W02017 / 211640 (Autostore Technology AS) describes a storage and retrieval system for storing product items, comprising a grid structure, a number of storage bins configured to be stored in vertical compartments in the grid structure, where each storage bin is configured to contain at least one product item, where the storage system comprises a picking and / or supply station; and where the storage system comprises a conveyor system configured to convey a storage bin from a first position to a second position and further to a third position. The conveyor system comprises a first, tiltable conveyor configured to convey the storage bin from the first position to the third position via the second position. The picking and / or supply station is provided adjacent to the grid structure. The first and third positions are provided below two different vertical compartments in the grid structure. The tiltable conveyor comprises a hydraulic piston and cylinder mechanism for lowering and elevating a conveyor. The tiltable conveyor supports a storage bin in an inclined position in the second position so allowing items to be manually picked from the storage bin. Once picked, the tiltable conveyor is tilted down and the storage bin is transported to a third position allowing for the storage bin to be retrieved by a load handling device operative on the grid structure. Lowering and elevating rollers using a hydraulic piston and cylinder mechanism not only suffers from alignment issues to make sure that a storage bin is able to be transported from the first position to the third positon via the second positon but the use of such a tiling device adds a level of complexity to the picking station.

[0015] In a typical grid framework structure, a majority of the grid columns are storage columns, i.e. grid columns where storage containers are stored in stacks. However, a grid normally has at least one grid column which is used not for storing storage containers, but which comprises a location where the load handling device can drop off and / or pick up storage containers so that they can be transported to a second location (not shown in the prior art figures) where the storage containers can be accessed from outside of the grid framework structure or transferred out of or into the grid. Within the art, such a location is normally referred to as a “port” and the grid column in which the port is located may be referred to as a “port column”. The storage grids may comprise two port columns or a single port column depending on whether separate ports columns are used to respectively drop off and pick up a storage container or whether the same port column can be used to drop-ff and pick up a storage column. For example, a first port column may be a dedicated drop-off port column where the load handling devices can drop off storage containers to be transported through the drop-off port column and further to an access station or an inventory handling station, and a second port column may comprise a dedicated pick-up port where the container handling vehicles can pick up storage containers that have been transported through the second port column from an access or a transfer station.

[0016] The access station may be a picking station where one or more items are picked from the storage container when fulfilling one or more customer orders or a decant station where one or more items are deposited into the storage containers for stocking the storage and retrieval system. Typically, when used as a picking station, a storage container removed from the grid framework structure is returned back into the grid framework structure. Typically, a conveyor system comprising a conveyor is employed to transport the storage containers between the first port column, the second port column and the inventory handling station.

[0017] Conventional inventory handling stations in the art tend to be a complicated arrangement of conveyors and driving mechanisms for moving one or more storage containers between one or more port columns and the inventory handling station. WO2018 / 069282 (Autostore Technology AS) describes a picking / supply station assembly for a storage system comprising a grid structure. The picking / supply station assembly comprises a first bin lift device, a second bin lift device and a picking / supply station, wherein the first bin lift device is arrangeable to receive a storage bin from the at least one vehicle at the top level of the grid structure and deliver the storage bin to the picking / supply station. WO 2020 / 074717 (Autostore Technology AS) describes an access station for picking storage containers, comprising: a picking zone, at least one conveyor arranged to transport storage containers from an entry position through said picking zone and to an exit position, wherein the access station comprises: at least one tilting device arranged to tilt a storage container at least in the picking zone. Like, the teaching in W02017 / 211640 (Autostore Technology AS), the tilting device tilts a storage container in the picking zone when the access station is to be operated with a picking person, thereby providing the ergonomic benefits of tilting.

[0018] Whilst the inventory handling stations described above are suitable to fulfil orders that is generally planned well in advance, e.g. a couple of days upon receipt of a customer order, there is no system available for the immediate fulfilment of a customer order, i.e. within a couple of hours upon receipt of a customer order. This is particularly the case where the order comprises a small number of generally staple items, e.g. bread or milk, and can also include the impulsive buying behaviour of a customer which have a tendency to buy goods without planning in advance. When a customer makes such buying decisions at the spur of the moment, it is usually triggered by emotions and feelings, i.e. making an unplanned purchase. Typically, convenience stores that stock a wide range of everyday items such as coffee, groceries, snack foods, confectionery, soft drinks, tobacco products, over-the-counter drugs, toiletries, newspapers, and magazines tend are best placed to cater for such an impulsive market. With the market for convenience stores and impulsive purchase increasing, an inventory handling station is thus required to fulfil an order for immediate dispatch.

[0019] In an attempt to simplify the inventory handling station, WO2017211596 (Autostore Tech AS) teaches a storage and retrieval system, wherein the grid framework structure comprises a drawer device. The drawer device comprises a storage container with a compartment for temporarily storing a product item to be picked from or supplied to the storage system. The drawer device is configured to be in a closed state or in an open state. A person is prevented from accessing the compartment when the drawer device is in the closed state and allowed to access to the compartment when in the open state. Likewise, WO2023274863 (Autostore Tech AS) teaches an access station comprising a frame structure and a drawer arranged in the frame structure comprising a compartment for accommodating a goods holder. The drawer is movable between a receiving position for receiving the goods holder from above and a picking position for presenting the goods holder to a user. In the receiving position, the drawer is retracted into the frame structure for preventing a user from accessing the compartment. The access station additionally comprises a blocker operational with the drawer for providing a safety zone (Zs) above the receiving position. The blocker is configured to block movement of the drawer located in the receiving position when an object is located in the safety zone (Zs), and to block movement of an obj ect into the safety zone (Zs) when the drawer (510) is at least partly located outside the receiving position. The safety zone safety mechanism prevent a user from being injured, in particular a user who has not been trained in the use of the access station, such as a customer picking up an order. However, in both the teachings, the access station requires a complicated arrangement of a frame structure and a drawer. An inventory handling station is thus required that:- i) is flexible and can double up as a pick station and / or a supply station, ii) is portable so that it can be retrofitted to any grid framework structure.

[0020] Summary of the Invention

[0021] The present applicant has mitigated the above problem by integrating an inventory handling station into the grid framework structure, more specifically into one of the storage columns of the grid framework structure such that a target storage container or contents therein, can easily be accessed without the need to take the target storage container to a separate inventory handling station outside of the grid framework structure. By integrating the inventory handling station into one of the storage columns of the grid framework structure reduces the cost to having a standalone inventory handling station adjacent to the grid framework structure. When using the inventory handling station as a pick station, it is essential that there are safety features present to prevent an operator’s hand inadvertently being trapped or caught under a storage container as it is being lowered down a storage column. To integrate an inventory handling station into the grid framework structure and yet, provide a safety zone within the grid framework structure to prevent injuring an operator’s hand when trying to access a storage container lowered down a storage column, the present invention provides a storage and retrieval system comprising: a grid framework structure comprising: - i) a track system for guiding the movement of one or more load handling devices on the grid framework structure, said track system comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells, ii) a supporting framework structure comprising a plurality of storage columns, each of the plurality of storage columns being arranged below the track system and being arranged to accommodate a stack of storage containers, said supporting framework structure comprising at least one port column arranged below the track system for dropping off and / or picking up a storage container, an inventory handling station comprising: i) a compartment for accommodating a storage container, said compartment being arranged vertically below the at least one port column and comprising a first opening for receiving a storage container lowered down the at least one port column along a first axis and a second opening for moving the storage container along a second axis, said second axis being substantially perpendicular to the first axis; ii) a door moveable between a first position in which the compartment is able to receive a storage container from the at least one port column through the first opening along the first axis and a second position in which the door is retracted into the at least one port column to form a barrier between the track system and the compartment such that a storage container is prevented from being lowered into the compartment through the first opening along the first axis; wherein a storage container is accessible through the second opening when the door is in the second position and the storage container is inaccessible via the second opening when the door is in the first position.

[0022] For the purpose of definition, a port column is a storage column in the supporting framework structure that is not presently being used to store one or more storage containers in a stack. However, the present invention is not limited to the port column to not being used to store one or more storage containers and can revert back to being a storage column. The inventory handling station is integrated into the port column such that a load handling device operable on the track system is able to lower a storage container vertically into the compartment of the inventory handling station that is accessible by an operator. To receive a storage container lowered by a load handling device, the compartment has a first opening vertically aligned with the at least one port column along a first axis. To access the storage container when lowered into the compartment, the compartment comprises a second opening extending in a direction along a second axis that is substantially perpendicular to the first axis. To provide a safety zone within the inventory handling station when an operator is trying to access a storage container lowered into the compartment of the inventory handling station, the door is moveable between a first position in which the compartment is able to receive a storage container from the at least one port column through the first opening along the first axis and a second position in which the door is retracted into the at least one port column to form a barrier between the track system and the compartment such that a storage container is prevented from being lowered into the compartment through the first opening along the first axis. Optionally, the door is guided by a guide track into a retracted position of the inventory handling station to form a physical barrier between the track system and the compartment. The guide track can be a track or rail integrated into the inventory handling station and as the inventory handling station is integrated into the at least one port column, the guide track can be integrated into the at least one port column of the grid framework structure. Optionally, the guide track comprises a horizontal portion extending into the inventory handling station (i.e., the at least one port column). To support the door in the retracted position, optionally, the guide track comprises a pair of depressions for accommodating the opposing edges of the door.

[0023] To respectively open and close the first opening and second opening in a single operational movement of the door, optionally, the guide track comprises an arcuate portion adjacent to the horizontal portion. The arcuate portion of the guide track helps to guide the door into the retracted position in a single lifting operation of the door. Optionally, the door comprises a bidirectional roller shutter in rolling engagement with the guide track between the open and closed positions. Alternatively, the door can be a single leaf door having at least an arcuate portion corresponding to the arcuate portion of the guide track. Alternatively, the door can be a single leaf door having a planar or flat surface rotatably mounted to the inventory handling station by a hinge mechanism, said hinge mechanism being configured to cooperate with the guide track to move the door into the retracted position. Having a single leaf door with a planar surface requires at least two operational movements of the door to move the door into the retracted position.

[0024] To automate the movement of the door between the first and second positions when a storage container is lowered into the compartment, the inventory handling station further comprises a motorised driving mechanism for moving the door between the first and second positions and a sensor for sensing the presence of a storage container in the compartment, said motorised driving mechanism being configured to move the door between the first and second positions in response to one or more signals from the sensor. For example, once the sensor sense the presence of a storage container in the compartment, a controller coupled to the sensor automatically moves the door via the motorised drive mechanism to the second position in order for an operator to retrieve the storage container in the compartment. Optionally, the sensor comprises a load cell or an optical sensor or a camera for detecting the presence of a storage container in the compartment.

[0025] To access the contents of the storage container lowered into the inventory handling station, optionally, the storage and retrieval system comprises a conveyor system configured to transport a storage container lowered into the compartment to a position external of the supporting frame structure; more specifically to an access zone external of the supporting framework structure.

[0026] A storage container can be lowered into and picked up from the same inventory handling station or a separate inventory handling station; each of the separate inventory handling stations having the same features as the inventory handling station of the present invention, i.e., a door moveable between first and second positions. The advantage of having separate inventory handling stations to respectively lower and pick up a storage container is that a storage container can be transported between different locations of the grid framework structure, i.e., through separate port columns. This removes the need to return the storage container back into the same port column that the storage container originally came from and thus, creating a bottleneck within the port column. To mitigate this problem, optionally, the at least one port column comprises a delivery port column and a pick up port column and the inventory handling station comprising a first inventory station and a second inventory station, said first inventory handling station being arranged below or within the delivery port column and the second inventory handling station being arranged below or within the pick-up port column, wherein the conveyor system is configured to transport a storage container from the first inventory handling station to the second inventory handling station via the access zone. The access zone represents an area of the conveyor system external of the supporting framework structure where the contents of the storage container are easily accessible. This could allow one or more items to be picked or deposited into the storage container. A storage container lowered in the first inventory handling station via the delivery port column can be transported to a second inventory handling station to be returned back to the grid framework structure via the pick-up port column. This operation removes the need to return the storage container back into the same inventory handling station creating a bottleneck at the port column. Moreover, having first and second inventory handling stations increases the throughput of storage containers through the access zone, which in turn increases the pick rate of items from the storage containers. To move a storage container from the first inventory handling station back into the grid framework structure via the second inventory handling station, optionally, the conveyor system is substantially U-shaped.

[0027] In addition to, or alternatively to returning the storage container back into the supporting framework structure by a substantially U-shaped conveyor system, the supporting framework structure can comprise a first supporting framework structure and a second supporting framework structure, the first supporting framework structure comprising the delivery port column and the second supporting framework structure comprising the pick-up port column, the first supporting framework structure being spaced apart from the second supporting framework structure by the conveyor system extending between the first and second supporting framework structures. Optionally, the track system bridges or extends across the first and second supporting framework structures so as to allow one or more load handling devices to move between the first supporting framework structure and the second supporting framework structure.

[0028] Optionally, the storage and retrieval system further comprise a picking device for picking one or more items from the storage container at the access zone. Optionally, the picking device can be a robotic arm having an end effector configured to pick the one or more items from the storage container. Optionally, the robotic arm can be mounted to a gantry to allow movement of robotic arm and thus, end effector in X, Y and / or Z orthogonal directions.

[0029] To provide further safety to an operator from being exposed to one or more storage containers being lowered or raised along a port column, at least one sidewall of the at least one port column comprises cladding. Preferably, the cladding extends externally of the supporting framework structure from the second opening to the track system. The cladding provides a covering external of the supporting framework structure such that the second opening is the only portion of the port column to gain access to a storage container lowered into the compartment. Optionally, the cladding extends around the outer perimeter sides of the supporting framework structure to define a storage space enclosed within the cladding, i.e., covering on all four sides of the supporting framework structure. Optionally, the cladding comprises a solid wall. Optionally, the cladding comprises thermal insulation material. Equipping the storage and retrieval system with a refrigeration system, the thermally insulated cladding allows the temperature of the storage space to be controlled or regulated to provide chilled temperature (typically temperatures between 1°C - 8°C) or freezer temperature (typically temperatures - 18°C to -30°C).

[0030] The present disclosure further provides a fulfilment centre for presenting one or more fulfilled orders to a user, comprising:

[0031] A) a grid framework structure comprising: i) a track system for guiding the movement of one or more load handling devices on the grid framework structure, said track system comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells, ii) a supporting framework structure comprising a plurality of storage columns to define a storage area for a plurality of containers, each of the plurality of storage columns being arranged below the track system, one or more of the plurality of storage columns being arranged to accommodate the plurality of containers in one or more stacks of containers, said supporting framework structure comprising at least one dispatch port column arranged below the track system for dropping off and / or picking up a container;

[0032] B) a delivery station comprising a drop off / pick-up position in communication with the at least one dispatch port column for receiving one or more containers lowered down the least one dispatch port column and a user interaction position accessible through an opening exterior of the fulfilment centre, said delivery station comprising i) a compartment for accommodating a storage container, said compartment being arranged below the at least one dispatch port column and comprising a first opening for receiving a storage container lowered down the at least one dispatch port column along a first axis and a second opening for moving the storage container along a second axis, said second axis being substantially perpendicular to the first axis; ii) a door moveable between a first position in which the compartment is able to receive a storage container from the at least one dispatch port column through the first opening along the first axis and a second position in which the door is retracted into the at least one dispatch port column to form a barrier between the track system and the compartment such that a storage container is prevented from being lowered into the compartment through the first opening along the first axis; wherein a storage container is accessible through the second opening when the door is in the second position and wherein the storage container is inaccessible via the second opening when the door is in the first position;

[0033] C) a load handling device comprising a grabber device operable to retrieve a container from a storage column of the plurality of storage columns and move the container on the track system;

[0034] D) a control system comprising a processor and memory storing instructions that when executed by the processor cause the processor to: i) instruct the load handling device to retrieve a target container from the storage area and transport the target container to the delivery station via the at least one dispatch port column; and ii) present the target storage container to the user interaction position in response to the control system receiving a signal from a local user interface. Optionally, the delivery station is integrated into the at least one dispatch port column.

[0035] Detailed Description

[0036] Further features and aspects of the present invention will be apparent from the following detailed description of an illustrative embodiment made with reference to the drawings, in which:

[0037] Figure 1 is a schematic diagram of a grid framework structure according to a known system,

[0038] Figure 2 is a schematic diagram of a top-down view showing a stack of bins arranged within the framework structure of Figure 1.

[0039] Figure 3 is a schematic diagram of a system of a known load handling device operating on the grid framework structure.

[0040] Figure 4 is a schematic perspective view of the load handling device showing the lifting device gripping a container from above.

[0041] Figure 5(a) and 5(b) are schematic perspective cut away views of the load handling device of Figure 4 showing (a) the container receiving space of the load handling device and (b) a container accommodating the container receiving space of the load handling device.

[0042] Figure 6(a, b and c) are perspective views of an inventory handling station integrated into a port column of the supporting framework structure according to a first example of the present invention; where (a) shows the door in the open position to enable a storage container to be delivered into the inventory handling station; (b) shows the door in an intermediate position and (c) shows the door in the closed position to prevent a storage container being lowered into the inventory handling station. Figure 7 is a perspective view of the grid framework structure incorporating the inventory handling station of Figure 6 showing the cladding extending across one face of the supporting framework structure.

[0043] Figures 8(a and b) are perspective views of a second example of the door integrated into the port column of the present invention, where (a) shows the door being guided by runners into the closed position to prevent a storage container being lowered into the inventory handling station; and (b) shows the door being guided by runners into the open position to enable a storage container to lowered into the inventory handling station.

[0044] Figure 9 is a perspective view of a third example of the door integrated into a port column of the supporting framework structure showing the door being guided by an arcuate shaped guide track.

[0045] Figure 10(a, b and c) are perspective views of an inventory handling station according to the third example of the present invention shown in Figure 9; where (a) shows the door in the open position to enable a storage container to be delivered into the inventory handling station; (b) shows the door in the closed position to prevent a storage container being delivered to the inventory handling station; and (c) shows an operator moving the storage container to a position external of the grid framework structure to access the contents of the storage container.

[0046] Figure 11 is a perspective view of the grid framework structure comprising a separate delivery port column and pick-up port column and the conveyor system adopting a U-shaped configuration to transport a storage container from the delivery port column to the pick-up port column.

[0047] Figure 12 is a perspective view of the grid framework structure showing a first supporting framework structure with a first inventory handling station for receiving a storage container, a second supporting framework structure with a second inventory handling station to pick up the storage container and a conveyor system for transporting the storage container from the first inventory handling station to the second inventory handling station via the access zone.

[0048] Figure 13 is a perspective view of the grid framework structure of Figure 12 showing the track system extending from the first supporting framework structure to the second supporting framework structure such that one or more load handling devices can move between the first and second supporting framework structures.

[0049] Figure 14(a and b) are schematic perspective views of a fulfilment centre comprising the storage and retrieval system shown in Figure 1 and a delivery station for delivery of a customer order to a user interaction position accessible through an opening exterior of the fulfilment centre; where (a) showing the door comprising a bi-directional roller shutter of the delivery station shown in Figure 8 in the closed position; and (b) showing the bi-directional roller shutter of the delivery station in the open position.

[0050] Figure 15 schematic perspective views of a fulfilment centre comprising the storage and retrieval system shown in Figure 1 and a delivery station comprising a single leaf door for delivery of a customer order to a user interaction position accessible through an opening exterior of the fulfilment centre

[0051] Detailed Description

[0052] It is against the known features of the storage system such as the grid framework structure and the load handling device described above with reference to Figures 1 to 5, the present invention has been devised. In a typical fulfilment centre, a large variety of items, such as grocery items are stored in storage bins or containers and the storage bins or containers are stored in one or more stacks in the grid framework structure, more specifically within one or more grid columns. The grid columns are formed by a plurality of upright members or vertical columns arranged as vertical storage locations. Individual containers may be stacked in vertical layers, and their locations in the grid framework structure or “hive” may be indicated using coordinates in three dimensions to represent the load handling device or a container’s position and a container depth (e.g. container at (X, Y, Z), depth W). Equally, locations in the grid framework structure may be indicated in two dimensions to represent the load handling device or a container’s position and a container depth (e.g. container depth (e.g. container at (X, Y), depth Z). For example, Z=1 identifies the uppermost layer of the grid framework structure, i.e. the layer immediately below the rail system, Z=2 is the second layer below the rail system and so on to the lowermost, bottom layer of the grid framework structure. A majority of the grid columns in the grid framework structure are storage columns.

[0053] To pick an order comprising different items, it is often necessary to retrieve items from multiple source containers. Such containers can be retrieved from the storage and retrieval system and brought to a desired order picking system. Specific containers required for fulfilment of orders are accessed by a robotic load handling device operative on the grid framework structure. The load handling device preferably comprises a control unit which receives control signals from a radio communications unit of a control system or a central control system concerning information on where to pick up and deliver a storage bin or container in the grid framework structure. The control system controls the operation of one or more load handling devices operative on the grid framework structure and comprises one or more processors, a memory (e.g., read only memory and random access memory) and a communication bus. The memory can be any storage device commonly known in the art and include but are not limited to a RAM, computer readable medium, magnetic storage medium, optical storage medium or other electronic storage medium which can be used to store data and accessed by the one or more processors. At least one of the storage columns is not used for storing containers and typically, comprises a location where a load handling device can drop off and / or pick up storage containers or bins to and from a pick or supply station. Within the art, such a location is normally referred to as a “port” and corresponds to the grid cell where a storage bin or container are dropped off or picked up. Depending on whether the port is located for drop off or pick up of a storage container, the storage column where the port is located may be referred to as a “port column”. The port column can be separate port columns located at a drop off port to cater for the drop off of storage containers and a “retrieval column” located at a pick-up port to cater for the pickup of storage containers or a single port column to cater for both the drop-off and pick-up of storage containers. In either case, the port column located at the drop-off port can be termed as a delivery port column and, equally, the port column located at the pick-up port can be termed as a pick-up port column.

[0054] As is commonly known in the art, items in the inventory are identified and tracked by a unique code called a SKU (stock keeping unit) that identifies a characteristic attribute about each item in the inventory, such as manufacturer, brand, style, colour, and size and help to distinguish different types of items in the inventory or stock, e.g., cheese of a particular brand. When a retailer takes inventory of its stock, it counts the quantity it has of each SKU. Palletized or other batches of items arrive at a container filling or restocking station. For example, pallet(s) of items may be removed from a truck or other means of conveyance at an order processing / fulfilling centre, and be wheeled into one or more storage bin or container filling stations. Typically, the filling station comprises trolleys, conveyors, trolleys etc. for holding a plurality of storage bins or containers. The filling station can receive either empty or partially filled storage containers. As desired, when stocking of storage containers or bins are complete, the storage containers may be transferred to storage in the storage and retrieval system, as for example, by conveyor, and stored therein until needed for fulfilment of an order. For example, a storage bin or container may be brought to a drop off port by an overhead load handling device operative on the grid framework structure and lowered to a picking station where one or more of items of the order can be picked into a destination or delivery container.

[0055] Typically, the picking station can double up as a restocking station. For the purpose of the present invention, the picking / restocking station may be referred to as an inventory handling station which has an access station or access zone that can function both as a picking station and / or a restocking station. The inventory handling station assembly cooperates with the storage and retrieval system to provide a fulfilment system for the fulfilment of one or more orders. Generally speaking, the pick station is a separate or standalone unit outside of the grid framework structure and therefore, occupies a footprint in addition to the footprint of the grid framework structure in a fulfilment or distribution centre. Not only does the inventory handling station extends the footprint of the grid framework structure, the inventory handling station tend to be costly and complex requiring multiple moving parts.

[0056] Figures 6(a, b and c) show at least a portion of the grid framework structure 42. The inventory handling station 44 according to the present invention is shown integrated into one of the storage columns 46 of the grid framework structure 42. The grid framework structure 42 comprises a supporting framework structure 48 for the storage of one or more stacks of storage containers 12 in one or more storage columns 50 and a track system 52 mounted to the supporting framework structure 48. The track system 52 comprises a plurality of tracks arranged in a grid pattern forming a plurality of grid cells for one or more load handling devices to move laterally in two dimensions on the supporting framework. The supporting framework structure 48 can be formed by a plurality of uprights members or vertical uprights 16 arranged at each of the intersections of the plurality of tracks of the track system (also known as nodes of the track system) to form a plurality of storage columns as discussed in PCT Patent Publication No. W02015 / 019055 (Ocado), the details of which are incorporated herein by reference. Typically, each of the plurality of upright members has a hollow centre cross section and four comer sections, each comer section comprises two perpendicular bin guiding plates for accommodating a comer of a storage container and for guiding a storage container along a storage column and through a respective grid cell.

[0057] Equally, the supporting framework structure 48 can comprise a plurality of prefabricated modular panels arranged in a three-dimensional grid pattern comprising a first set of parallel prefabricated modular panels extending in the first direction and a second set of parallel prefabricated modular panels extending in the second direction to define a plurality of grid cells as taught in WO2022034195 (Ocado Innovation Limited). The prefabricated modular panels are arranged such that each of the grid cells of the supporting framework structure is sized to support a subset of the plurality of grid cells of the track system, i.e., each of the grid cells of the supporting framework structure is sized to support a plurality of grid cells of the track system. To guide one or more structure containers through a grid cell of the track system, the supporting framework structure comprises a plurality of tote guides. Like the vertical members of the grid framework structure discussed above, the plurality of tote guides is arranged to form a plurality of storage columns for the storage of one or more storage containers in stacks. The inventory handling station 44 shown in Figures 6(a, b and c) occupies at least one of the storage columns 50 of the supporting framework structure not used for the storage of storage containers (i. e. , a port column 46). This removes the need to have a separate inventory handling station outside of the grid framework structure. To gain access to a storage container 10, the port column 46 accommodating the inventory handling station 44 is positioned at one of the storage columns accessible externally of the supporting framework structure. The inventory handling station is arranged vertically below the port column 46 and comprises a compartment 54 suitable to accommodate a storage container 10 lowered down the port column 46. To receive a storage container, the compartment 54 comprises a first opening 56 arranged vertically below the port column 46 for receiving a storage container lowered down the port column along a first axis, Z-Z and a second opening 58 for moving the storage container along a second axis, X-X, i.e., the first axis is substantially parallel to the longitudinal axis of the port column (see Figure 6(c)). To move the storage container to a position where the contents of the storage container can be accessed externally of the supporting framework structure, the second axis, X-X, is substantially perpendicular to the first axis.

[0058] Also shown in Figures 6(a, b and c) is a conveyor system 60 extending from a position inside the port column 46 to a position external of the supporting framework structure to assist with the moving of a storage container lowered into the compartment through the second opening 58 along the second axis, X-X. The conveyor system 60 can be a manual conveyor system comprising a plurality of passive rollers 62 that are configured to rotate when an object such as a storage container is moved across the conveyor or a motorised conveyor comprising one or more drive rollers to transport the storage container along the conveyor. Other conveyor systems known in the art to transport one or more storage container in a direction along the second axis to a position external of the supporting framework structure are applicable in the present invention. These include but are not limited to a belt driven conveyor system or a pneumatic driven conveyor system. In the particular example shown in Figures 6(a, b and c), the conveyor system comprises a plurality of passive rollers 62 mounted to a frame 64 to elevate the conveyor system above ground level, usually at waist level, such that a storage container transported by the conveyor system is in easy reach of a standing operator. The portion of the conveyor system extending into the port column can be defined as a drop-off zone or a pickup zone 66 depending whether a storage container is dropping a storage container into the inventory handling station or picking up a storage container from the inventory handling station. An operator 68 can reach into the port column and physically pull the storage container from the drop-off zone 66 to a position external of the supporting framework structure as shown in Figure 6c. The portion of the conveyor system external of the supporting framework structure where the operator can access the contents of the storage container can, thus, be termed an access zone 67 (see Figure 7).

[0059] However, one of the requirements when integrating the inventory handling station into the port column of the supporting framework structure is the risk that an operator may inadvertently reach out into the port column when a load handling device is lowering a storage container into the inventory handling station. Considering that a storage container may weigh in excess of 30kg, reaching out into the port column may result in accidents such as trapped fingers or worse, injury from falling debris down the port column. To mitigate such accidents, the inventory handling station additionally comprises a door 70 that not only closes the second opening 58 to prevent the operator 68 from reaching into the inventory handling station but doubles up a safety barrier to prevent a subsequent storage container from being lowered into the compartment of the inventory handling station through the first opening 56. To close the first opening 56 and thereby, prevent a storage container being lowered into the inventory handling station, the door 70 shown in Figures 6(a, b and c) comprises a single leaf that is moveable between a retracted position into the port column as shown in Figure 6(c) and an open position to enable a storage container to be lowered into the inventory handling station as shown in Figure 6(a). In the retracted position, the door extends into the port column to provide a safety zone 72 below the door. The safety zone 72 can represent an area of the port column between the drop-off zone or pick-up zone 66 of the conveyor system and the door 70 in the retracted position to enable an operator to reach out into the port column without risk of injury, i.e., the area below the door 70 (see Figure 6(c).

[0060] The door 70 is shown movably connected to the port column, more specifically to the vertical uprights or tote guides of the supporting framework structure, by a hinge mechanism 74 and moveable between a first position to close the second opening 58 as shown in Figure 6(a) and a second position to open the second opening 58 as shown in Figure 6(c). The first position of the door coincides with the open position of the door to enable a storage container to be lowered into the inventory handling station (compartment) and the second position of the door coincides with the retracted position of the door to prevent a storage container being lowered into the inventory handling station (compartment). The retracted position of the door is shown in Figure 6(c), whereby in the retracted position, the door forms a physical barrier between the track system and the compartment. In the particular example shown in Figures 6(a, b and c), the single leaf door has a substantially planar or flat surface. As a result of the substantially planar surface of the door, there is also an intermediate position when moving the door between the first and second positions of the door as shown in Figure 6(b). To move the door to the second position, it is necessary to rotate the door about the hinge mechanism to an intermediate position before being moved to the retracted position. Thus, retrieving a storage container lowered into the inventory handling station comprises a two-stage process involving rotating the door from the first position to the intermediate position and finally, retracting the door into the port column in the second position. When in the intermediate position, the hinge mechanism cooperates with a pair of guide tracks 76 formed in the sidewalls of the port column to enable the door to be moved to the retracted position as shown in Figure 6(b), i.e., the hinge mechanism comprises one or more runners 78 that cooperate with the pair of guide tracks to enable the door to be moved into the retracted position. The guide tracks 76 are shown as a pair of elongated depressions formed in the sidewalls of the port column. The elongated depressions in the sidewalls of the port column are configured to accommodate the opposing edges of the door when the door is moved into the retracted position. However, the guide tracks are not limited to elongated depressions and can be other forms of guides to guide and support the door when moved into the retracted position. Examples include one or more beads or elongated protrusions that cooperate with corresponding depressions along opposing edges of the door. To ensure that the door is guided into a substantially horizontal position when the door is in the retracted position, the guide track comprises a substantially horizontal portion. The different stages of the movement of the door changes the orientation of the door from a substantially vertical orientation to a substantially horizontal orientation is shown in Figures 6(a and c).

[0061] The guide tracks are configured to accommodate the opposing edges of the door and sufficient to provide a load bearing support for supporting the weight of one or more storage containers when the door is in the retracted position. Considering that a typical storage container weighs 30kg, the door has a load bearing capacity in excess of 30kg when supported by the guide tracks. Thus, should one or more storage containers or even items contained therein accidently fall down a port column when an operator is reaching into the inventory handling station, the door functions as a physical barrier preventing injury to the operator.

[0062] Also shown in Figures 6(a, b and c) and in particular in Figure 7, is cladding 80 extending across the external face of the supporting framework structure accommodating the inventory handling station to provide a barrier or covering between the operators or pickers and the supporting framework structure. In the particular example shown in Figure 7, the cladding 80 comprises a solid wall extending across at least one face of the storage columns and extending from the track system to the floor. To retrieve a storage container or contents therein lowered down a port column, the cladding 82 at the port column is shorter and extends from the guide tracks to the track system to form the second opening adjacent the compartment of the inventory handling station. As discussed above, the second opening is closable by the door to block access to the port column externally of the supporting framework structure. Whilst the cladding is shown covering one face of the supporting framework structure, the cladding can extend across the all of the external faces or outer perimeter sides of the supporting framework to define a storage space within the confines of the cladding, i.e., the supporting framework structure is enclosed or encased within the cladding extending across all four sides of the supporting framework structure. The cladding can comprise solid insulated walls, e.g., the use thermal insulation material (e.g., glass fibre, polystyrene etc). Encasing or enclosing the supporting framework structure in cladding comprising thermal insulation material allows the temperature within the storage space to be controlled or regulated by a refrigeration system to store goods or items at chilled (typically temperatures between 1°C - 8°C) or freezer temperature (typically temperatures -18°C to -30°C). In addition to the cladding comprising thermal insulation material and to prevent the ingress of heat into the storage space via the second opening, the door itself can comprise thermal insulation material. In addition to integrating the inventory handling station into a port column, the advantage of enclosing the supporting framework structure in thermal insulating cladding is the ability to retrieve and return the storage container to and from the port column without greatly affecting the temperature of the contents of the storage container. For example, the door can be moved to the first and second positions to respectively close and open the second opening relatively quickly mitigating the ingress of heat into the storage space via the second opening. To further prevent the ingress of heat into the storage space when the door opens the second opening, the inventory handling station can additionally comprise an air curtain to create a barrier of air extending across the second opening.

[0063] Instead of the door being configured as a single leaf having a substantially planar or flat surface that requires two modes of operations to move the door between the first and second positions, in another example of the present invention, the door can be a bi-directional roller shutter 170 as shown in Figures 8(a and b). In addition to having a substantially horizontal portion 84a, the guide track comprises an arcuate or curved portion 84b and optionally, a vertical portion 84c extending from the conveyor system 60. The different portions of the guide track are connected together to provide a continuous guide surface for the bi-directional roller shutter 170. The bidirectional roller shutter is configured to conform to the arcuate shape of the guide track as it is guided along the guide track. To conform to the arcuate shape of the guide track, the bidirectional roller shutter 170 comprises a plurality of hinged panels 86 so as to enable the bidirectional roller shutter to bend around the arcuate portion 84b of the guide track 76 as shown in Figure 8(a). In operation when retrieving a storage container lowered down a port column, an operator 68 lifts the bi-directional roller shutter 170 to cause the bi-directional roller shutter to move to the second position as shown in Figure 8(a). In the second position, the bi-directional roller shutter is retracted into the port column 46 so forming a safety barrier between the track system and the compartment of the inventory handling station to prevent further a storage container being lowered into the compartment. To close the second opening 58 and enable a storage container 10 to be lowered into the compartment, the operator applies a downward force to cause the bi-directional roller shutter to move to the first position as shown in Figure 8(b). The advantage of the bi-directional roller shutter over a single leaf or panel door discussed above with reference to Figures 6(a, b and c) is the ability to move the door between the first and second positions in a single movement of the door.

[0064] In yet a further example of the present invention, the door can be a single leaf door 270, wherein at least a portion of the door has a curved or arcuate shape that is configured to be guided by a correspondingly shaped arcuate guide track 88 as shown in Figure 9. Like the bi-directional roller shutter discussed above with reference to Figures 8(a and b), the arcuate shaped door 270 can be moved between the first and second positions to respectively close and open the second opening in a single movement operation of the door. When retrieving a storage container lowered down the port column onto the drop-off or pick-up zone, an operator lifts the door 270 in a single movement operation to cause the door 270 to move to the second position as shown in Figure 10(b). In the second position, the door is retracted into the port column preventing storage containers being lowered onto the drop-off or pick-up zone and causing the second opening for retrieving the storage container from the port column to be open. Once at the second position, the operator 68 can reach into the port column and retrieve the storage container. In the example shown in Figure 10(c), the storage container is lowered onto passive rollers and the operator 68 can simply pull the storage container from out of the port column to a position external of the port column to the access zone 67 for accessing the contents therein. In all of the different examples of the door discussed above, movement of the door between the first and second positions can be automated. For example, the inventory handling station may comprise a motorised drive mechanism (not shown) for moving the door between the first and second positions. Actuating movement of the door may comprise a sensor for sensing the presence of a storage container in the compartment of the inventory handling station. The sensor can comprise a load cell or an optical sensor or a camera for detecting the presence of a storage container in the compartment. A controller in communication with the sensor and the motorised drive mechanism can be configured to actuate movement of the door in response to one or more signals from the sensor indicative of the presence of a storage container in the compartment. Alternatively, a switch or button can manually actuate the motorised drive mechanism to move the door between the first and second positions. For example, once a storage container is to be retrieved from the drop-off zone or to be dispensed with into the pickup zone, an operator may actuate the motorised drive mechanism by pushing the button or switch to open the door.

[0065] The same inventory handling station can be used to drop-off and pick-up a storage container in the port column. However, the problem with using the same inventory handling station to dropoff and pick-up a storage container is a reduction in the number of storage containers that can be processed at the inventory handling station. This is turn may cause a reduction in the pick rate of one or more items from the storage containers to fulfil one or more customer orders. The rate at which storage containers can be processed through the inventory handling station may have also an impact on the congestion of one or more load handling devices at track level waiting for the port column to be free. To mitigate this problem and to increase the rate at which the storage containers can be processed through the inventory handling station, the inventory handling station can comprise a first inventory station 90a and a second inventory handling station 90b and the port column can comprise a delivery port column 146a and a separate pick-up port column 146b as shown in Figures 11, 12 and 13 The first inventory station is arranged below or within the delivery port column for receiving storage containers dropped off at the drop-off zone and the second inventory handling station is arranged below or within the pick-up port column for picking up storage containers delivered at the pick-up zone. The first and second inventory handling stations comprise any of the same features as the inventory handling station discussed above, i.e., a door moveable between first and second positions. Separating the inventory handling station into first and second inventory handling stations to drop-off and pick-up a storage container respectively not only increases the rate at which storage containers can be processed to fulfil one or more customer orders but reduces the congestion of one or more load handling devices at track level, particularly at the port. This is particularly advantageous when the storage space within the supporting framework structure is controlled or regulated to provide a controlled temperature, e.g., chilled or freezer storage temperature.

[0066] To gain access to the content of the storage containers externally of the supporting framework structure, the first inventory handling station 90a is spaced apart from the second inventory handling station 90b by the conveyor system 160 as shown in Figure 11. The conveyor system 160 extends from the drop-off zone within the delivery port column 146a to the pick-up zone within the pick-up port column 146b. Thus, a storage container dropped off at the drop off zone is transported to the second inventory handling station to be picked up by a load handling device operating on the track system. The access zone 67 for picking one or more items from the storage container is interposed between the first and second inventory handling stations 90a, 90b. The first inventory station can be spaced apart from the second inventory handling station in the same supporting framework structure 48 as shown in Figure 11 or separate supporting framework structures 148a, 148b as shown in Figures 12 and 13. In Figure 11, the conveyor system 160 adopts a U-shaped configuration to transport a storage container from the delivery port column to the pick-up port column via the access zone 67, i.e. the delivery and pick-up port columns 146a, 146b being separate port columns within the supporting framework structure. The delivery port column and the pick port column are shown in Figure 11 accessible from the same face or side of supporting framework structure. However, the delivery port column and the pick-up port column do not necessarily need to be on the same face and can be accessible from different faces or sides of the supporting framework structure.

[0067] In contrast to having the delivery port column and the pick-up port column in the same supporting framework structure, the delivery port column 146a and the pick-up port column 146b can be in separate supporting framework structures as shown in Figure 12 and 13. In the example shown in Figures 12 and 13, the supporting framework structure comprises a first supporting framework structure 148a and a second supporting framework structure 148b, the first supporting framework structure 148a comprises the delivery port column 146a and the second supporting framework structure 148b comprises the pick-up port column 146b. The first supporting framework structure is shown spaced apart from the second supporting framework structure by the conveyor system 67 extending from the delivery port column 90a to the pick-up port column 90b. Like the arrangement shown in Figure 11, a storage container lowered onto the drop-off zone in the first supporting framework structure 148a is transported to the pick-up zone in the second supporting framework structure 148b. Thus, a storage container moved from the drop-off zone at the delivery port column to the access zone 67 for picking can be subsequently moved to the pick-up zone at the pick-up port column to be stored in the supporting framework structure. In the example shown in Figure 12, the storage container is stored in the second supporting framework structure and in the example shown in Figure 13, the storage container can be returned to either the first supporting framework structure 148a or the second supporting framework structure 148b. In the example shown in Figure 13, the track system 52 extends across the conveyor system 60, i.e., the track system bridges the first and second supporting framework structures 148a, 148b, such that a load handling device operating on the track system can move between the first and second supporting framework structures. Due to the ability of the load handling device to travel across the conveyor system, a storage container picked up at the pick-up zone by a load handling device operating on the track system can either stored in the first supporting framework structure or the second supporting framework structure. For safety reasons, a trap (not shown) can extend below the track system bridging the first and second supporting framework structures to prevent debris falling onto the conveyor system between the first and second supporting framework structures, particularly the picking area around the access zone. The trap can be a net or a solid barrier.

[0068] Whilst not shown in the drawings, one or more items picked from one or more storage containers at the access zone 67 can be deposited into one or more delivery containers used to transport the one or more items to customer’s destinations. For example, one or more delivery containers can be presented to the operator at the access zone during a picking operation. Various ways in which the delivery containers can be presented to the operator during a picking operation. These include but are not limited to the use of a trolley, a separate conveyor system or manually presenting the delivery container to the operator. One of the advantages of integrating the inventory handing station into the port column is also the ability to fulfil late customer orders. This could be, for example, where a customer has requested a last-minute addition or change to his / her order. The customer’s order can be returned to the inventory handling station, which may include the customer’s delivery container, and the storage container containing the missing item can be quickly retrieved from storage in the grid framework structure. Picking of the one or more items at the access zone can also be automated by a picking device comprising a robotic picking arm comprising an end effector for picking the one or more items from the storage container. The inventory handling station described above is not limited to functioning as a pick station but can operate as a decant station in the sense that one or more items can be decanted into one or more storage containers at the access zone to replenish stock in the support framework structure. For example, the inventory handling station in all of the different examples of the present invention discussed above can be used to deposit fresh storage containers into the grid framework structure or stock can be reintroduced into existing storage containers by retrieving the storage containers from the grid framework structure.

[0069] In a traditional brick and mortar store-based commerce, goods are typically distributed in a sequence from the manufacturer, to the wholesaler, to the retailer, and finally to the customer. Retail shops function as the end points of the distribution chain that a delivery carrier involves. The customers mostly have to take care of the ‘last mile’ transportation of goods, i.e. delivery from the physical point of purchase to home; the end of the distribution chain may be extended to the consumer’s households.

[0070] However, this is largely not the case with e-commerce where products purchased online are transported from a distribution centre to either a collection point accessible by a customer or directly to a customer’s home in a timely manner. As a result, the development of online shopping has led to a plethora of different e-commerce models for the purchase of goods online. These range from the click and collect model where customers purchasing or selecting goods online can either pick the goods up in a store of choice or at a centralized collection location or a home delivery service where goods are delivered directly to the customer’s premises. Whilst home delivery services eliminate the need for customers to travel to the store to pick up their shopping, there is still a desire for customers to pick up one or more items, particularly bulky items, from the retailer. Online delivery of goods offers convenience, but it comes with several disadvantages. Here are some examples of the disadvantages, shipping delays due to weather, logistics issues, or high demand periods (e.g., holidays) can be frustrating; items may not match descriptions or photos; customers can't inspect products before buying, leading to potential dissatisfaction with quality, size, or fit; extra charges for delivery, especially for express shipping or international orders, can make purchases more expensive; products can arrive damaged due to improper handling during shipping. Moreover, whilst home delivery to fulfil customer orders is generally planned well in advance, e.g. a couple of days upon receipt of a customer order, there are a few systems available for the immediate fulfilment of a customer order, i.e. within a couple of hours upon receipt of a customer order. This is particularly the case where the order comprises a small number of generally staple items, e.g., bread or milk, and can also include the impulsive buying behaviour of a customer which have a tendency to buy goods without planning in advance. When a customer takes such buying decisions at the spur of the moment, it is usually triggered by emotions and feelings, i.e., making an unplanned purchase. Typically, convenience stores that stock a wide range of everyday items such as coffee, groceries, snack foods, confectionery, soft drinks, tobacco products, over-the-counter drugs, toiletries, newspapers, and magazines tend are best placed to cater for such an impulsive market. With the market for convenience stores and impulsive purchase increasing, a delivery station is thus required to fulfil an order for immediate dispatch.

[0071] Whilst home delivery services eliminate the need for customers to travel to the store to pick up their shopping, there is still a desire for customers to pick up one or more items, particularly bulky items, from the retailer. Online delivery of goods offers convenience, but it comes with several disadvantages. Here are some examples of the disadvantages, shipping delays due to weather, logistics issues, or high demand periods (e.g., holidays) can be frustrating; items may not match descriptions or photos; customers can't inspect products before buying, leading to potential dissatisfaction with quality, size, or fit; extra charges for delivery, especially for express shipping or international orders, can make purchases more expensive; products can arrive damaged due to improper handling during shipping. Moreover, whilst home delivery to fulfil customer orders is generally planned well in advance, e.g. a couple of days upon receipt of a customer order, there are a few systems available for the immediate fulfilment of a customer order, i.e. within a couple of hours upon receipt of a customer order. This is particularly the case where the order comprises a small number of generally staple items, e.g., bread or milk, and can also include the impulsive buying behaviour of a customer which have a tendency to buy goods without planning in advance. When a customer takes such buying decisions at the spur of the moment, it is usually triggered by emotions and feelings, i.e., making an unplanned purchase. Typically, convenience stores that stock a wide range of everyday items such as coffee, groceries, snack foods, confectionery, soft drinks, tobacco products, over-the-counter drugs, toiletries, newspapers, and magazines tend are best placed to cater for such an impulsive market. With the market for convenience stores and impulsive purchase increasing, a delivery station is thus required to fulfil an order for immediate dispatch.

[0072] According to a second aspect of the present disclosure, the inventory handling station may alternatively be configured to deliver one or more fulfilled items directly to a customer, bypassing a traditional home delivery service. To distinguish this from the inventory handling station described above which is intended for picking items associated with a customer order — this second aspect redefines the station's role as a delivery station. In this configuration, the delivery station presents one or more completed orders to a customer at a fulfilment or distribution centre. While the structural and operational features of the inventory handling station, as described with reference to Figures 6 to 10, remain applicable, its primary function in this context (hereinafter referred to as the 'delivery station') is to facilitate the handover of fulfilled customer orders.

[0073] More specifically, the present invention provides a fulfilment centre 162 (as shown Figures 14(a and b) and Figure 15) for presenting one or more fulfilled orders 164 to a user 166, comprising:

[0074] A) a grid framework structure 14 comprising: i) a track system 15 for guiding the movement of one or more load handling devices 30 on the grid framework structure 14, said track system comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells, ii) a supporting framework structure 248 comprising a plurality of storage columns 50 to define a storage area for a plurality of storage containers, each of the plurality of storage columns being arranged below the track system and being arranged to accommodate the plurality of storage containers in one or more stacks of storage containers, said supporting framework structure comprising at least one dispatch port column 172 arranged below the track system 15 for dropping off and / or picking up a storage container;

[0075] B) a delivery station 144 comprising a drop off / pick up position 178 in communication with the at least one dispatch port column 172 for receiving one or more storage containers 164 lowered down the least one dispatch port column 172 and a user interaction position 180 accessible through an opening 174 exterior of the fulfilment centre 162;

[0076] C) a load handling device comprising a grabber device operable to retrieve a storage container from a storage column of the plurality of storage columns and move the storage container on the track system;

[0077] D) a control system comprising a processor and memory storing instructions that when executed by the processor cause the processor to: i) instruct the load handling device to retrieve a target storage container from the storage area and transport the target storage container to the delivery station 144 via the at least one dispatch port column 172; and ii) present the target storage container to the user interaction position in response to the control system receiving a signal from a local user interface.

[0078] By integrating the delivery station 144 into the grid framework structure that is able to receive a target storage container retrieved from the storage area and present the target storage container through an opening exterior of the fulfilment centre, the fulfilment centre can cater for home delivery as well as click and collect pick-up at the fulfilment centre. The fulfilment centre can be a distribution centre than offers home delivery service as well as a pick-up service, e.g., a curb side pick-up. The fulfilment centre 162 can comprise a dedicated curb-side pick station comprising a lane for a vehicle 168 to pick up their order.

[0079] The target storage container is defined as a storage container comprising a customer order of one or more items that has been requested by a customer for collection at the delivery station. The local user interface can any type of input device that can generate a signal when operated. Examples of such input devices include but is not limited to a keyboard, a Bluetooth receiver, an image scanner, a microphone, pointing device, a biometric input device, a face recognition device, an iris recognition device, a retina recognition device, a near field communication reader, a radio frequency identification reader, a linear and / or matrix barcode reader, a payment card reader, a smart card reader, an infra-red reader.

[0080] To present the customer order to the customer at the fulfilment centre, optionally, the delivery station comprises a transport mechanism 176 configured to transport one or more target storage containers between the drop off position and the user interaction position. The drop-off position and the user interaction position can be the same position or separate positions. The drop off position 178 being a position within the at least dispatch port column 172. Thus, a load handling device operable on the track system can be instructed by the control system to retrieve the target storage container from the storage area and deliver the target storage container to the delivery station 144 via the at least one dispatch port column 172. A transport mechanism 176 transports the target container from the drop-off position 178 to the user interaction position 180 for the customer to retrieve their order (see Figures 14(b) and Figure 15). Optionally, the transport mechanism comprises a conveyor system configured to convey the one or more containers in a substantial lateral direction between the drop-off position and the user interaction position. Alternatively, or in addition to the conveyor system, the transport mechanism can comprise a vertical carousel (not shown) comprising at least one carrier configured to receive the target container and a drive mechanism configured to circulate the at least one carrier around a vertical endless loop between the drop-off position / ick-up and the user interaction position. Thus, instead of conveying the target container laterally between the drop-off position and the user interaction position, the load handling device operative on the track system can retrieve the target container from the storage area and deliver the target container to the vertical carousel via the at least one dispatch port column. Optionally, the drive mechanism comprises a drive shaft and at least one arm extending radially outwardly from a first end connected to the drive shaft to a second end rotatably connected to the at least one carrier. Optionally, the at least one carrier comprises a plurality of carriers, said drive mechanism being configured to circulate each of the plurality of carriers around the vertical endless loop between the drop-off / pick-up position and the user interaction position. The plurality of carriers rotates about a substantially horizontal rotational axis such that one of the plurality of carriers is in communication with the at least dispatch port column defining the drop-off position and the other of the plurality of carriers is accessible through the opening exterior of the fulfilment centre defining the user interaction position. Optionally, the control system is operatively coupled to the drive mechanism and is configured to index the plurality of carriers around the endless vertical loop in sequential steps, each of the sequential steps corresponding to at least one of the plurality of carriers being in the drop-off / pick-up position and the other of the plurality of carriers being in the user interaction position.

[0081] In addition to the transport mechanism being able to transport a storage container between the drop-off position and the user interaction position, optionally, the transport mechanism can comprise one or more buffer positions for temporarily storing one or more storage containers. In the case where the transport mechanism comprises a conveyor system, the conveyor system can be sized to accommodate one or more buffer positions in addition to the drop-off position and the user interaction position. For the vertical carousel, one or more of the plurality of carriers can buffer one or more storage containers subsequent to being dropped-off by a load handling device and prior to be moved to the user interaction position.

[0082] To prevent inadvertent access to the user interaction position, optionally, the delivery station comprises a door mechanism 170, 270 operable to selectively: i) close the opening 174 of the delivery station to a closed position to prevent access to the drop-off position 178 and / or the user interaction position 180; ii) open the opening of the delivery station to an open position to gain access of the drop-off position and / or the user interaction position exterior of the fulfilment centre.

[0083] The door mechanism can comprise an access control module or an actuation mechanism (e.g., solenoid) to control the operation of the door between a closed position as shown in Figure 14(a) and an open position as shown in Figure 14(b). Optionally, the door mechanism comprises a door that can be selectively opened to grant access to the drop-off position and / or user interaction position and a closed position to prevent access to the user interaction position. Optionally, the fulfilment centre further comprises an access control module for controlling the operation of the door mechanism between an open position and closed position to grant or deny access to the drop-off position and / or the user interaction position, said access control module is operatively coupled to the control system to present the target storage container to the user at the delivery station by actuating the door mechanism to the open position in response to the signal from the local user interface. To grant access to the drop-off position and / or the user interaction position when the target storage container is at the drop-off position and / or the user interaction position, optionally, the delivery station comprises an occupancy sensor for sensing the presence of one or more target containers at the drop-off position and / or the user interaction position, said control system is configured to control the access control module to grant access to the drop-off position and / or the user interaction position in response to a signal from the occupancy sensor. In response to sensing the presence of the target storage container at the drop-off position and / or the user interaction position, the occupancy sensor provides a signal to the control system to operate the access control module to open the door and allow the customer to collect his / her order. The occupancy sensor can sense the presence of a target container in the compartment and sends a signal to the control system to actuate a locking mechanism to move the door to the open position. The signal from the occupancy sensor can also provide a signal to the control system that the contents of the target storage container have been retrieved by the customer. For example, the occupancy sensor can be a load cell that determines the weight of the target container at the user interaction position before and after the contents of the target storage container have been removed; the difference in the weight of the target container providing an indication that the contents of the target container have been retrieved. Other examples of the occupancy sensor include but is not limited to infrared sensors, ultrasonic sensors and camera-based sensors or a vision system. Optionally, the door mechanism comprises a bi-directional roller shuter, said bi-directional roller shuter being selectively positionable between: i) the closed position to prevent access to the drop-off position and / or the user interaction position and allow a storage container to be lowered into the drop-off position; and ii) the open position to grant access to the drop-off position and / or the user interaction position and to prevent a container of the plurality of storage containers being lowered into the drop-off position.

[0084] The door can be a bi-directional roller shuter 170 as shown in Figures 14(a and b) and described in further detail above with reference to Figure 8 or a single leaf door 270 as shown in Figure 15 and described with reference to Figures 9, 10(a to c). The advantage of the bidirectional roller shuter over other types of doors is that in a single operation of the roller shuter the roller shuter selectively; (i) permits a load handling device lowering a target container into the drop-off position and / or the user interaction position when access to the dropoff position and / or the user interaction position is prevented; and (ii) prevents a load handling device lowering a storage container into the drop-off position when access to the drop-off position and / or the user interaction position is granted.

[0085] Optionally, the load handling device comprises a plurality of load handling devices operable on the track system. Optionally, the fulfilment centre comprises an inventory handling station for picking one or more items from one or more of the plurality of containers, and wherein the supporting framework structure further comprises at last one port column in communication with the inventory handling station for the load handling device to drop off and / or pick up one or more of the plurality of containers to and / or from the inventory handling station. The inventory handling station is a station where the contents of the storage can be accessed outside the storage area for picking one or more items from one or more containers when fulfilling one or more customers’ orders. The inventory handling station can be the inventory handling station described above with reference to Figures 6 to 12 or another type of inventory handling station. Examples of such inventory handling stations is described in WO2021 / 239559 (Ocado Innovation Limited), the details of which is incorporated herein by reference.

[0086] In the present disclosure, retrieval of the target container from the storage area for dispatch to the customer can, optionally, takes precedence over the other operations of the load handling device in the fulfilment centre. Optionally, the control system is configured to prioritise instructions to one or more of the plurality of load handling devices to retrieve the target storage container from the storage area based on their operational status on the track system in response to receiving the signal from the local user interface. The operational status being defined as the status of the one or more load handling devices on the track system when the control system receives a signal from the local user interface to retrieve the target storage container from the storage area. Optionally, the operational status being the one or more of the plurality of load handling devices being inactive on the track system for a predetermined amount of time. The predetermined amount of time can be the duration of time that the load handling device is inactive on the track system prior to performing an operation on the track system. To prioritise retrieval of the target storage container from the storage area over the other operations on the track system, optionally, the control system is configured to override one or more instructions to one or more of the plurality of load handling devices to retrieve the target storage container in response to the signal from the local user interface based on their operational status. Examples of such one or more instructions that can be overridden include but is not limited to retrieval of one or more storage containers for delivery to the inventory handling station.

[0087] To fulfil one or more customers’ orders via the delivery station, optionally, the control system comprises a customer database comprising data associated with a plurality of customer orders; and wherein the control system in response to receiving the signal from the local user interface is configured to: i) correlate the signal to a customer order in the customer database; ii) identify the target container unique to the customer order in the storage area; iii) instruct the load handling device to retrieve the target container from a storage location in the storage area and transport the target storage container to the delivery station via the at least one dispatch port column.

[0088] The present invention provides a method of dispatching a target storage container from a fulfilment centre according to the present disclosure; the method comprising the steps of: i) identify a target storage container in a storage location in the storage area in response to receiving the signal from the local user interface; ii) interrupting one or more instructions of the load handling device to retrieve a container from the storage area; iii) providing instructions to the load handing device to retrieve the target storage container from the storage location and transport the target storage container to the delivery station.

[0089] Subsequent to delivering the target container to the delivery station, optionally, the method further comprises the step of resuming the one or more instructions to the load handling device to retrieve the container from the storage area.

Claims

Claims1. A storage and retrieval system comprising:A) a grid framework structure comprising: - i) a track system for guiding the movement of one or more load handling devices on the grid framework structure, said track system comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells, ii) a supporting framework structure comprising a plurality of storage columns, each of the plurality of storage columns being arranged below the track system and being arranged to accommodate a stack of storage containers, said supporting framework structure comprising at least one port column arranged below the track system for dropping off and / or picking up a storage container;B) an inventory handling station comprising: i) a compartment for accommodating a storage container, said compartment being arranged below the at least one port column and comprising a first opening for receiving a storage container lowered down the at least one port column along a first axis and a second opening for moving the storage container along a second axis, said second axis being substantially perpendicular to the first axis; ii) a door moveable between a first position in which the compartment is able to receive a storage container from the at least one port column through the first opening along the first axis and a second position in which the door is retracted into the at least one port column to form a barrier between the track system and the compartment such that a storage container is prevented from being lowered into the compartment through the first opening along the first axis; wherein a storage container is accessible through the second opening when the door is in the second position and wherein the storage container is inaccessible via the second opening when the door is in the first position.

2. The system of claim 1, wherein the inventory handling station is integrated into the at least one port column.

3. The system of claim 1 or 2, further comprising a guide track for guiding the door into the second position.

4. The system of claim 3, wherein the guide track comprises a top horizontal portion extending into the inventory handling station.

5. The system of claim 3, wherein the guide track comprises an arcuate portion adjacent the top horizontal portion.

6. The system of any one of the claims 3 to 5, wherein the guide track comprises a pair of depressions for accommodating the opposing edges of the door into the retracted position.

7. The system of any one of the claims 3 to 6, wherein the door is rotatably mounted to the inventory handling station by a hinge mechanism, said hinge mechanism being configured to cooperate with the guide track to move the door into the retracted position.

8. The system of any one of the claims 3 to 7, wherein the door comprises a bi-directional roller shutter in rolling engagement with the guide track between the first and second positions.

9. The system of any one of the preceding claims, wherein the inventory handling station further comprises a motorised driving mechanism for moving the door between the first and second positions and a sensor for sensing the presence of a storage container in the compartment, said motorised driving mechanism being configured to move the door between the first and second positions in response to one or more signals from the sensor.

10. The system of any one of the preceding claims, further comprising one or more load handling devices operating on the track system, each load handling device comprising: a driving assembly configured to move the load handling device on the track system;a grabber device configured to releasably hold a storage container from above; and a lifting assembly configured to raise and lower the grabber device into and out of the supporting framework structure via the grid cells.

11. The system of any one of the preceding claims, further comprising a conveyor system configured to transport a storage container lowered into the compartment to an access zone external of the supporting framework structure.

12. The system of claim 11, wherein said at least one port column comprises a delivery port column and a pick up port column and the inventory handling station comprises a first inventory handling station and a second inventory handling station, said first inventory handling station being arranged within or below the delivery port column and the second inventory handling station being arranged within or below the pick-up port column, wherein the conveyor system is configured to transport a storage container from the first inventory handling station to the second inventory handling station via the access zone.

13. The system of claim 12, wherein the supporting framework structure comprises a first supporting framework structure and a second supporting framework structure, the first supporting framework structure comprising the delivery port column and the second supporting framework structure comprising the pick-up port column, the first supporting framework structure being apart from the second supporting framework structure by the conveyor system extending between the first and second supporting framework structures.

14. The system of claim 13, wherein the track system extends between the first and second supporting framework structures so as to allow one or more load handling devices to move between the first supporting framework structure and the second supporting framework structure.

15. The system of any one of the claims 11 to 14, further comprising a picking device for picking one or more items from the storage container at the access zone.

16. The system of claim 15, wherein the picking device comprises a robotic picking arm having an end effector configured to pick one or more items from a storage container at the access zone.

17. The system of any one of the preceding claims, wherein at least one sidewall of the at least one port column comprises cladding.

18. The system of claim 17, wherein the cladding extends externally of the supporting framework structure from the second opening to the track system.

19. A fulfilment centre for presenting one or more fulfilled orders to a user, comprising:A) a grid framework structure comprising: i) a track system for guiding the movement of one or more load handling devices on the grid framework structure, said track system comprising a plurality of tracks arranged in a grid pattern comprising a plurality of grid cells, ii) a supporting framework structure comprising a plurality of storage columns to define a storage area for a plurality of containers, each of the plurality of storage columns being arranged below the track system, one or more of the plurality of storage columns being arranged to accommodate the plurality of containers in one or more stacks of containers, said supporting framework structure comprising at least one dispatch port column arranged below the track system for dropping off and / or picking up a container;B) a delivery station comprising a drop off / pick-up position in communication with the at least one dispatch port column for receiving one or more containers lowered down the least one dispatch port column and a user interaction position accessible through an opening exterior of the fulfilment centre, said delivery station comprisingi) a compartment for accommodating a storage container, said compartment being arranged below the at least one dispatch port column and comprising a first opening for receiving a storage container lowered down the at least one dispatch port column along a first axis and a second opening for moving the storage container along a second axis, said second axis being substantially perpendicular to the first axis; ii) a door moveable between a first position in which the compartment is able to receive a storage container from the at least one dispatch port column through the first opening along the first axis and a second position in which the door is retracted into the at least one dispatch port column to form a barrier between the track system and the compartment such that a storage container is prevented from being lowered into the compartment through the first opening along the first axis; wherein a storage container is accessible through the second opening when the door is in the second position and wherein the storage container is inaccessible via the second opening when the door is in the first position;C) a load handling device comprising a grabber device operable to retrieve a container from a storage column of the plurality of storage columns and move the container on the track system;D) a control system comprising a processor and memory storing instructions that when executed by the processor cause the processor to: i) instruct the load handling device to retrieve a target container from the storage area and transport the target container to the delivery station via the at least one dispatch port column; and ii) present the target storage container to the user interaction position in response to the control system receiving a signal from a local user interface.

20. The fulfilment centre of claim 19, wherein the delivery station is integrated into the at least one dispatch port column.

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