Storage and retreival system

Abstract

A retail fulfillment system for order filling of goods items, the system comprising: a multilevel container storage array, each level of which has a transport area and a storage area, the storage area including an array of storage shelves configured to hold thereon containers of at least one of the goods items; an autonomous guided container transport vehicle located on each level of the multilevel storage array; a lift communicably connecting the storage shelves of the array to a conveying output feeding picked goods items containers to an order fill output station; a putwall of more than one levels of picked goods items container cache shelves, at each level; and a controller configured to effect operation of the autonomous guided container transport vehicle between one or more of the container storage locations, and at least one picked goods items container cache storage shelf of the putwall, and of the lift.

Description

Aty. Docket No. 1127P017282-WO (PCT)STORAGE AND RETREIVAL SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a non-provisional of and claims the benefit of United States provisional patent application number 63 / 701,983 filed on October 01, 2024, the disclosure of which is incorporated here by reference in its entirety.BACKGROUND1. Field

[0002] The present disclosure generally relates to warehousing, and more particularly, to automated warehousing systems.2. Brief Description of Related Developments

[0003] Generally, a back of store fulfillment center picks orders for customers by sourcing items from a number of supply totes, and placing them into order totes that will be delivered to a customer. Once prepared, the order totes must be buffered until the customer arrives for pickup. Customers tend to arrive in waves, so buffered order totes must be accessible quickly and in high volumes. Storage density and labor efficiency are also important.

[0004] A related problem for a back of store fulfilment center is that many items are contained within the sorting system, but others must be picked directly from store shelfs. The items picked from the store must be matched with items picked from the sorting system for the same order. Additionally, traditionally items are picked from the store one order at a time, which is very labor intensive because the picker may traverse the entire store for every order.

[0005] Accordingly, the present disclosure addresses a number of those issues.Aty. Docket No. 1127P017282-WO (PCT)BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The foregoing aspects and other features of the present disclosure are explained in the following description, taken in connection with the accompanying drawings, wherein:

[0007] Figs. 1A-1C are exemplary top view illustrations of a retail fulfillment system in accordance with the present disclosure;

[0008] Fig. 2 is an exemplary perspective illustration of a portion of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure;

[0009] Fig. 3 is an exemplary side view illustration of a portion of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure;

[0010] Fig. 4 is an exemplary perspective illustration of a portion of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure;

[0011] Fig. 5 is an exemplary side view illustration of a portion of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure;

[0012] Fig. 6 is an exemplary side view illustration of a portion of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure;

[0013] Fig. 7 is an exemplary side view illustration of a portion of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure;

[0014] Fig. 8 is an exemplary schematic side view illustration of a floor roving hot of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure;

[0015] Fig. 9 is an exemplary schematic top view illustration of a portion of the retail fulfillment system of Figs. 1 A-1C in accordance with the present disclosure; andAty. Docket No. 1127P017282-WO (PCT)

[0016] Fig. 10 is an exemplary method flow chart of an operation of the retail fulfillment system of Figs. 1A-1C in accordance with the present disclosure.DETAILED DESCRIPTION

[0017] The following detailed description is meant to assist the understanding of one skilled in the art, and is not intended in any way to unduly limit claims connected or related to the present disclosure.

[0018] The following detailed description references various figures, where like reference numbers refer to like components and features across various figures, whether specific figures are referenced, or not.

[0019] The word “each” as used herein refers to a single object (i.e., the object) in the case of a single object or each object in the case of multiple objects. The words “a,” “an,” and “the” as used herein are inclusive of “at least one” and “one or more” so as not to limit the object being referred to as being in its “singular” form.

[0020] Fig. 1 A illustrates an exemplary automated retail fulfillment system 100 in accordance with the present disclosure. Although the present disclosure will be described with reference to the drawings, it should be understood that the present disclosure can be embodied in many forms. In addition, any suitable size, shape or type of elements or materials could be used. It is further noted that the terms picked item(s) and picked good(s), item good(s), are interchangeable and refer to goods unit(s) picked from a shipping container or case for retail in retail environment. Similarly, the terms tote(s), contained s), case(s), etc. are interchangeable and refer to storage units where the goods units are placed for storage in the retail fulfillment system 100.

[0021] The automated retail fulfillment system 100 may be disposed in a retail store or may be disposed in a distribution center, for example, to fulfill orders received from individual retail customers or fulfill orders received from retail stores, for replenishment of goods. The automatedAty. Docket No. 1127P017282-WO (PCT) retail fulfillment system 100 includes at least a storage and retrieval section 130. The automated retail fulfillment system may be substantially similar to that described in International patent application number PCT / US25 / 48733 filed on September 30, 2024 and titled “Back Store Fulfillment System and Method”, the disclosure of which is incorporated herein by reference in its entirety. Referring also to Figs. 2 and 3, the storage and retrieval section 130 includes a transfer deck BOB and storage racks 130R. The storage and retrieval section 130 includes picking aisles 130A that extend between adjacent storage racks 13 OR, where the picking aisles 130A are in communication with the transfer deck BOB so that at least one autonomous transport vehicle or bot 110 of the storage and retrieval section 130 may traverse along the transfer deck BOB, the picking aisles 130A and transition between the transfer deck BOB and picking aisles BOA.

[0022] The storage and retrieval section 130 has a common array store 180 with multiple environmental zones or stores Zl, Z2, Z3. The environmental zone Z1 may be configured to store frozen items, the environment zone Z2 may be configured to store chilled (below ambient temperatures but above freezing temperatures) items, and the environment zone Z3 may be configured to store items at ambient temperatures. Each environmental zone Z1-Z3 may be substantially isolated from each other environment zone Z1-Z3 in any suitable manner, such as by a strip curtain, door, or in any other suitable manner. Each environmental zone Z1-Z3 may have respective vehicles 110 operating therein, where the vehicles 110 operating in one environmental zone Z1-Z3 are separate and distinct from the vehicles 110 operating in other different environmental zones Z1-Z3. Each environment zone Z1-Z3 may include define a multilevel container storage array, each level of which has a transfer deck BOB, picking aisles 130A and storage area. The storage area including an array of storage racks BOR configured to hold thereon totes / containers CU of at least one goods items. The transfer deck BOB and picking aisles BOA being substantially continuous and arranged to communicably connect storage racks BOR of the array to each other.

[0023] There may be automated transfer stations ZTS disposed between adjacent environmental zones Z1-Z3 for transferring totes CU between the different environment zones Z1-Z3. While theAty. Docket No. 1127P017282-WO (PCT) transfer stations ZTS are illustrated between the frozen environmental zone Z1 and the chilled environmental zone Z2, there may be transfer stations ZTS between the chilled environmental zone Z2 and the ambient environmental zone Z3 and / or between the frozen environmental zone Z1 and the ambient environmental zone Z3. One or more of the transfer stations ZTS may be a static shelf where the vehicles 110 (or a lift 150) transfers the tote CU to and from the static shelf for transitioning between zones Z1-Z3 and / or one or more of the transfer stations ZTS may be an active station including an active transfer device that receives totes CU from the vehicles 110 and extends or pushes the received tote CU to a destination location, such as a vehicle 110 or lift 150 for transitioning between environmental zones Z1-Z3. The active station may include more than one degree of freedom of movement for moving a tote CU vertically and / or in any direction in a horizontal plane.

[0024] As can be seen in Fig. IB, the storage and retrieval section 130 is coupled to and feeds an output section 160UT (including an output pick station 160EP and putwall 160CB for preparing customer orders) in the manner described in International patent application number PCT / US25 / 48733 filed on September 30, 2025, the disclosure of which was previously incorporated by reference herein in its entirety. For example, picked goods item containers OT may be, for description purposes, referred to as order totes, wherein the order totes hold product goods picked at a picking station 160IP from a shipping case (or tote) and placed into the order tote. The picked goods in the order tote may be of the same kind, or mixed kind, and may correspond in part or in whole to a customer order. For example, all goods (whether of the same or mixed kind) in an order tote may be (correspond) in entirety to a single customer order (picking up the order at the retail facility or more than one customer order.

[0025] Order totes OT may be stored in the output section 160UT in more than one levels of picked goods items container cache storage rows 160CBl-n distributed along each level that may be connected to a back of store for pickup by customers or may be positioned intervening the storage and retrieval section 130 and output pick station 160EP so as to provide a cache for holding orderAty. Docket No. 1127P017282-WO (PCT) tote OT corresponding to customer orders until consolidation of the entire customer order for pickup.

[0026] The array of container cache storage rows 160CB l-160CBn is configured as a putwall. The array of container cache storage rows 160CBl-160CBn forms a wall of order totes OT within the retail fulfillment system 100 for batch picking of goods and adding the goods to completed retail customer orders from the corresponding order totes OT.

[0027] The putwall discriminates and sorts each picked goods order tote OT to a common order, enabling (for multiple disparate orders) rapid batch picking, which is much more labor efficient than picking by order. In the event items are also picked in store, such can be matched up and combined with items picked within the sortation system (effectively the putwall 160CB) resulting in additional savings in system throughput requirements and cost.

[0028] These rows 160CBl-160CBn form the putwall of totes along the bottom edge of one site of the storage array structure 130. This positioning of the putwall provides for a more efficient picking process, where order totes OT can be used as a “putwall” to enable the batch picking process. Rather than picking one order at time from the entire system 100, order fill pickers may be located at the output station 160EP (not shown) at the output section 160UT and can pick items for many orders at once, all within one section of the system 100.

[0029] The putwall may receive totes from any of the environmental zones Z1-Z3. Portions of the putwall may correspond to (or form a part of) an environmental zone Z1-Z3 or portions of the putwall may be a mixed environmental zone.

[0030] Fig. 1C illustrates an exemplary filling of the putwall. The putwall may be filled in the manner described in International patent application number PCT / US25 / 48733, filed on September 30, 2025, the disclosure of which was previously incorporated by reference herein in its entirety. The retail fulfillment system 100 may be configured with a consolidation section 185 from which a manual (or automated) picker 1501 may pick items for placement in an order toteAty. Docket No. 1127P017282-WO (PCT)OT held in the putwall. For example, any suitable automation or human operators may provide for the consolidation of fast moving items / stock keeping units SKUs (the fast moving items may be taken from the storage and retrieval section 130 in any suitable manner and / or taken from an input of the storage and retrieval section (such from a depalletizer or delivery truck on a pallet) for consolidation in the consolidation section 185). There may be an ambient consolidation section 185A, having environmental conditions similar to those in zone Z3, for consolation of fast moving items from the ambient environmental zone Z3. There may be a chilled consolidation section 185 A, having environmental conditions similar to those in zone Z2, for consolation of fast moving items from the chilled environmental zone Z2. There may be an frozen consolidation section 185F, having environmental conditions similar to those in zone Zl, for consolation of fast moving items from the ambient environmental zone Zl. As illustrated in Fig. 1C, the items are segregated or otherwise discriminated by the environment (e.g., such as of environmental zones Z1-Z3) at which they are to be stored in the consolidation section 185.

[0031] The storage and retrieval section 130 includes one or more storage levels 130Ll-130Ln, where each storage level includes a respective transfer deck I 30B and each picking aisle 130 A of each storage level 130Ll-130Ln includes vehicle riding surface(s) 200. Each storage level 130L1 - 130Ln may include more than one pick level PL1-PL4. While each storage level 130Ll-130Ln is illustrated as having four pick levels PL1-PL4, the storage levels may have more than four or less than four pick levels and a number of pick levels of one storage level may be different than a number of pick levels of another, different, storage level.

[0032] The storage racks 13 OR include an upright 205 (shown for example as a single representative upright member, however, a lift car may be engaged and supported from the putwall structure, riding the upright of the putwall structure). With reference also to Fig. 5, the upright 205 has a box frame 205F with spars 205 S extending from opposite sides of the box frame 205F. The storage racks BOR may be provided in modular sections BORM where the modular sections BORM are coupled to the box frame 205F of the upright 205 by the spars 205 S and are supported by the spars 205S. Each modular section BORM may have any suitable length RL and any suitableAty. Docket No. 1127P017282-WO (PCT) height RH. For exemplary purposes only, the modular section I 30RM is illustrated as having a length RL configured so that each pick level PL1-PL4 of the modular section ISORM holds six totes CU however, the length RL may be configured to hold any suitable number of totes CU, such are more or fewer than six totes CU. Case unit or tote supports 210 are cantilevered from the modular section 130RM so as to extend from opposite sides of the modular section 130RM. The storage racks 130R include vehicle riding surface supports 215 that are cantilevered from the upright 205 and configured to support and couple with a respective vehicle riding surface(s) 200.

[0033] The case unit or tote supports 210 are configured to support case units or totes CU such that the totes CU hang from the supports 210. For example, referring also to Fig. 4, the totes CU each include a collar or rim CUR that engages and seats on adjacent supports 210 so that the tote CU is stably supported by and hung from the adjacent supports 210. A vertical and horizontal spacing between the supports 210 may be any suitable vertical and horizontal spacing to accommodate a tote of any suitable height and width. For example, in Fig. 4 the totes CU are illustrated as having substantially the same width W but different heights Hl, H2 however, the totes may have the same height, different heights, the same width, or different widths. Storing totes of differing heights Hl, H2 (or mixed totes) may provide for different sized totes containing the same type of goods / items where the totes with the smaller height H2 are picked for filling smaller orders and the totes with the larger height Hl are picked for filling larger orders. The storage of the mixed totes provides for a higher storage density of the storage and retrieval section 130 which may increase the throughput (e.g., input and / or output of totes to and from the storage and retrieval section 130) based on variable order sizes fulfilled by the retail fulfillment system 100. The higher density and increased number of totes CU within the storage and retrieval section 130 may increase the frequency of occurrence of a particular item / good (e.g., in a tote having the smaller height H2 for smaller orders) within any given picking aisle 130A.

[0034] Referring again to Figs. 2 and 3, the vehicles 110 are configured to pick and place totes CU to and from storage spaces of shelves SP formed by the supports 210 (where adjacent supports 210 form or otherwise define a storage space SP at a respective pick level PL1-PL4 of a storageAty. Docket No. 1127P017282-WO (PCT) level 13OLl-13OLn). As an example, the vehicles 110 are configured to traverse a picking aisle 130 A and locate a predetermined tote CU in a predetermined storage space SP in any suitable manner (such as including but not limited to vision systems, encoders, optical sensors, capacitive sensors, etc.). The vehicle riding surfaces 200 may include rails that have thereon apertures, targets, or other sensor detectable features 450 (see Fig. 4) that effect location of the vehicle 110 within the picking aisle 130A. The vehicles 110 include a payload bay 110B having a payload bed HOD and transfer arm or end effector 110A. The transfer arm 110A is configured to extend from each lateral side of the vehicle 110 (i.e., in opposite directions) so as to pick and place totes CU from storage spaces SP on both sides 130AS1, 130AS2 of a picking aisle BOA. The vehicle 110 may include a mast 110M configured to raise and lower at least the transfer arm 110A to each of the pick levels PL1-PL4 for picking or placing totes CU to the storage spaces SP. The transfer arm 110A may be configured to pull or slide the totes CU from the supports 210, and push or slide the totes CU to the supports 210 to transfer the totes CU to and from the storage spaces SP.

[0035] Referring to Figs. 1, 9, 7, and 6, the operator pick station 160EP may include one or more vehicle delivery aisle 900 configured so that the vehicles 110 may traverse between the transfer deck 130B and the vehicle delivery aisle 900 for delivering totes CU from the storage and retrieval section 130 to the operator pick station 160EP. One or more buffer shelves may be provided where the vehicle 110 may place totes CU on the buffer shelves 910 for sorting totes CU at the operator pick station 160EP. For example, a vehicle may place a tote (tote A) at one buffer shelf and pick another tote (tote B) from another buffer shelf and transport the other tote to a different buffer shelf (different than the one and the other buffer shelf) at the same or different operator pick station 160EP. A secondary sortation device 920 (e.g., conveyor, lift, etc.) may be provided. An input / output conveyor 930 may be provided to transport totes CY to and from one or more operator stations 940 of the operator pick station 160EP. A tote stacker / destacker may be provided for stacking empty totes from the operator stations 940 or destacking empty totes transferred to the operator stations 940 by the conveyor 930.Aty. Docket No. 1127P017282-WO (PCT)

[0036] Figs. 6 and 7 illustrate exemplary lifts 600, 700 that may be provided for at least transferring totes CU or picked goods items containers OT between the different storage levels 130Ll-130Ln of the array and / or different levels of the cache storage rows 160CBl-160CBn. The lifts 600, 700 may be any suitable lifts including, but not limited to, mast lifts, climbing bots, and ribbon or band lifts.

[0037] The lifts 600, 700 may include a load handling device or end effector 610 configured to extend in opposite directions (bi-directional extension - see arrow BDE) for picking and placing totes CU and picked goods items containers OT to storage or transfer locations (e g., storage spaces SP or) on opposite sides of the lift 600, 700.

[0038] Still referring to Fig. 7, the lift 700 is provided (the lift 600 may also be provide) adjacent lift cache 710 (i.e., picked goods items container cache storage locations 710A-710n of the putwall 160CB) that effects temporary positioning of picked goods items containers OT transferred by the lift 700.

[0039] The lift 700 communicably connects the storage shelves SP of the array to a conveying output feeding picked goods items containers OT to the output section 160UT.

[0040] The load handling device 610 is disposed to transfer containers OT to and from the lift 700 in more than one direction, each direction describing a corresponding side of the lift 700. The lift 700 may be positioned between two container cache storage rows 160CBl-160CBn of the putwall 160CB (i.e., the lift 700 may access more than one level of picked goods items container cache shelves 710, at each level, adjacent to each corresponding side of the lift 700.

[0041] Each cache shelf 710 is disposed to form a row of picked goods items container cache storage locations 710A-710n so that the autonomous guided container transport vehicle 110 on each level communicates with cache storage locations 710A-710n in the row 160CBl-160CBn, and so that the load handling device 610 of the lift 700 transfers a picked goods items containerAty. Docket No. 1127P017282-WO (PCT)OT to and from each cache storage location 710A-710n of the putwall 160CB with at least one of the more than one different directions.

[0042] The lift 700 may have more than one lift arranged in series in the putwall 160CB, so that each cache storage location 710A-710n of the putwall 160CB is accessed by at least one of the respective lifts in at least one of the more than one directions.

[0043] The system 100 may include a controller 799 configured to effect operation of autonomous guided container transport vehicle 110 and the lifts 700.

[0044] For example, the controller 799 configured to effect operation of the autonomous guided container transport vehicle 110 between one or more of the container storage locations SP, and at least one picked goods items container cache storage locations 710A-710n of the putwall 160CB.

[0045] The controller 799 may further be configured to effect operation of the lift 700 transferring the picked goods items container OT from each cache storage locations 710A-710n of the putwall 160CB to the conveying output (i.e., conveyor 730) feeding each goods items container from the putwall 160CB to the order fill output station 160EP.

[0046] In Fig. 7 the cache shelves 710A-710n are illustrated as having substantially the same width but different heights H3, H4 however, the cache shelves 710A-710n may have the same height, different heights, the same width, or different widths. Storing picked goods items containers OT of differing heights (or mixed containers) may provide for different sized containers containing the same type of goods / items where the containers with the smaller height are picked for filling smaller orders and the containers with the larger height are picked for filling larger orders.

[0047] The storage of the mixed containers may provide for a higher storage density of the storage and retrieval section 130, which may increase the throughput based on variable order sizes fulfilled by the retail fulfillment system 100. Alternatively, the higher density and / or increased number ofAty. Docket No. 1127P017282-WO (PCT) picked goods items containers OT within the putwall 160CB may be utilized for high use containers storing an increased frequency of occurrence of a particular item / good being ordered.

[0048] As noted above, the picked goods items containers OT may be sorted at the putwall 160CB, where the sortation may be performed in a manner similar to that described in United States patent number 10,947,060 issued on March 16, 2021 and titled “Vertical Sequencer for Product Order Fulfillment,” the disclosure of which is incorporated herein by reference in its entirety. Filling of the putwall cache storage locations 710A-710n at levels may be in a stochastic manner to effect an optimized distribution and facilitate optimum sortation and output of order totes in accordance with filling customer orders and the output section 160UT.

[0049] The conveying output feeding each container is a common output from the putwall to each order fill output station. The conveyor 930 (in an inbound operation) may transfer totes CU from the operator stations 940 to the lift 700. The conveyor 730 (which may be the conveyor 930 in an outbound operation) may transfer picked goods items containers OT from the lift 700 at the putwall 160CB to the operator stations 160EP. It is noted where picked goods items containers OT are transported to the lift 700 from the storage and retrieval section 130, the lift 700 may sort the picked goods items containers OT . The conveyor 730 feeding each picked goods items containers OT is a common output from the putwall 160CB to each order fill output station 160EP.

[0050] Referring to Figs. 1A-1C and 8, the retail fulfillment system 100 may include floor roving hots 800 that are configured to traverse a facility floor to transport totes CU between at least one or more of the operator pick stations 160EP, an order pickup area, the consolidation section 185, and the putwall 160CB. The floor roving bots 800 may include more than one arm or end effector 810A, 810B that are movably connected to the hot frame 800F at different levels or heights. The end effectors 810A, 810B are vertically movable by any suitable drive system 800D of the bot 800 so as to pick or place a tote CU (e.g., the tote having the height Hl or the height H2) from a stack of totes CUS, where the more than one end effector 810A, 810B configure the floor roving bot 800 for carrying at least two stacked totes CU.Aty. Docket No. 1127P017282-WO (PCT)

[0051] Referring now to Fig. 10, a method of fulfilling an order of goods in the items retail fulfillment system 100 is illustrated. The method includes providing a multilevel container storage array (Block 1000, Fig. 10) having the transport area and the storage area, the storage area including the array of storage shelves SP for holding thereon containers OT of at least one of the goods items, and the transport area being substantially continuous and arranged to communicably connect the storage shelves SP to each other, the transport area including picking aisles 130A and a container transfer deck 130B connecting the picking aisles 130A. The method further includes providing the autonomous guided container transport vehicle 110 for traversing the container transfer deck and picking aisles on each level and transporting containers for at least one goods items order picking station (Block 1001, Fig. 10). The lift 700 is provided to communicably connect the storage shelves SP to conveying output (conveyor 730) feeding picked goods items containers OT to the order fill output station 160EP. The end effector 610 transfers containers to and from the lift 700 in more than one direction. The picked goods items containers OT are transferred (for holding) to the putwall 160CB having more than one level of picked goods items container cache shelves 710A-710n adjacent to each corresponding side of the lift 700 (Block 1002, Fig. 10). The controller 799 effects operation of the autonomous guided container transport vehicle 110 between one or more of the container storage locations SP, and at least one picked goods items container cache storage shelf 710A-710n of the putwall 160CB, and of the lift 700 transferring the picked goods items container OT from each cache storage location 710A-710n to the conveying output (conveyor 730) feeding each goods items container OT from the putwall 160CB to the order fill output station 160EP (Block 1004, Fig. 10).

[0052] The following are provided in accordance with the present disclosure and may be employed individually, in any combination with each other, and / or in any combination with the features described above:

[0053] In accordance with the present disclosure a retail fulfillment system for order filling of goods items including:Aty. Docket No. 1127P017282-WO (PCT)

[0054] a multilevel container storage array, each level of which has a transport area and a storage area, the storage area including an array of storage shelves configured to hold thereon containers of at least one of the goods items, and the transport area being substantially continuous and arranged to communicably connect storage shelves of the array of storage shelves to each other, the transport area including picking aisles and a container transfer deck connecting the picking aisles,

[0055] an autonomous guided container transport vehicle, distinct from the container transfer deck, located on each level of the multilevel storage array and configured to traverse the container transfer deck and picking aisles on each level and transport containers accessed to and from container storage locations on each of the storage shelves on each level of the multilevel storage array for at least one goods items order picking station,

[0056] a lift communicably connecting the storage shelves of the array to a conveying output feeding picked goods items containers to an order fill output station, the lift having an end effector disposed to transfer containers to and from the lift in more than one direction, each direction describing a corresponding side of the lift,

[0057] a putwall of more than one levels of picked goods items container cache shelves, at each level, adjacent to each corresponding side of the lift, each cache shelf being disposed to form a row of picked goods items container cache storage locations so that the autonomous guided container transport vehicle on each level communicates with cache storage locations in the row, and so that the end effector of the lift transfers a picked goods items container to and from each cache storage location of the putwall with at least one of the more than one different directions, and

[0058] a controller configured to effect operation of the autonomous guided container transport vehicle between one or more of the container storage locations, and at least one picked goods items container cache storage shelf of the putwall, and of the lift transferring the picked goods itemsAty. Docket No. 1127P017282-WO (PCT) container from each cache storage location of the putwall to the conveying output feeding each goods items container from the putwall to the order fdl output station.

[0059] In accordance with the present disclosure the conveying output feeding each container is a common output from the putwall to each order fill output station.

[0060] In accordance with the present disclosure the lift has more than one respective lifts arranged in series in the putwall, so that each cache storage location of the putwall is accessed by at least one of the respective lifts in at least one of the more than one directions.

[0061] In accordance with the present disclosure each of the picked goods items container cache shelves are configured as one of a high usage cache or a low usage cache for holding respective high usage picked goods items containers and low usage picked goods items containers.

[0062] In accordance with the present disclosure one of the directions describing a corresponding side of the lift is configured for accessing the high usage cache shelves and another direction is configured for accessing the low usage cache shelves.

[0063] In accordance with the present disclosure the each picked goods items container cache shelf has a corresponding height.

[0064] In accordance with the present disclosure the corresponding height of at least one picked goods items container cache shelf is different from other picked goods items container cache shelves.

[0065] In accordance with the present disclosure the lift is configured to sort the picked goods items containers into a predetermined order on the picked goods items container cache shelves.

[0066] In accordance with the present disclosure the lift is configured so as to resequence the picked goods items containers and effect a change in the ordered sequence of the picked goods items containers held at the picked goods items container cache shelves.Aty. Docket No. 1127P017282-WO (PCT)

[0067] In accordance with the present disclosure a method of fulfilling an order of goods items in a retail fulfillment system including

[0068] providing a multilevel container storage array, each level of which has a transport area and a storage area, the storage area including an array of storage shelves for holding thereon containers of at least one of the goods items, and the transport area being substantially continuous and arranged to communicably connect storage shelves of the array of storage shelves to each other, the transport area including picking aisles and a container transfer deck connecting the picking aisles,

[0069] providing an autonomous guided container transport vehicle, distinct from the container transfer deck, located on each level of the multilevel storage array for traversing the container transfer deck and picking aisles on each level and transporting containers accessed to and from container storage locations on each of the storage shelves on each level of the multilevel storage array for at least one goods items order picking station,

[0070] providing a lift communicably connecting the storage shelves of the array to a conveying output feeding picked goods items containers to an order fill output station, the lift having an end effector disposed for transferring containers to and from the lift in more than one direction, each direction describing a corresponding side of the lift,

[0071] providing a putwall of more than one levels of picked goods items container cache shelves, at each level, adjacent to each corresponding side of the lift, each cache shelf being disposed to form a row of picked goods items container cache storage locations so that the autonomous guided container transport vehicle on each level communicates with cache storage locations in the row, and so that the end effector of the lift transfers a picked goods items container to and from each cache storage location of the putwall with at least one of the more than one different directions, andAty. Docket No. 1127P017282-WO (PCT)

[0072] effecting, with a controller, operation of the autonomous guided container transport vehicle between one or more of the container storage locations, and at least one picked goods items container cache storage shelf of the putwall, and of the lift transferring the picked goods items container from each cache storage location of the putwall to the conveying output feeding each goods items container from the putwall to the order fill output station.

[0073] In accordance with the present disclosure the conveying output feeding each container is a common output from the putwall to each order fill output station.

[0074] In accordance with the present disclosure the lift has more than one respective lifts arranged in series in the putwall, so that each cache storage location of the putwall is accessed by at least one of the respective lifts in at least one of the more than one directions.

[0075] In accordance with the present disclosure each of the picked goods items container cache shelves are configured as one of a high usage cache or a low usage cache for holding respective high usage picked goods items containers and low usage picked goods items containers.

[0076] In accordance with the present disclosure one of the directions describing a corresponding side of the lift is configured for accessing the high usage cache shelves and another direction is configured for accessing the low usage cache shelves.

[0077] In accordance with the present disclosure the each picked goods items container cache shelf has a corresponding height.

[0078] In accordance with the present disclosure the corresponding height of at least one picked goods items container cache shelf is different from other picked goods items container cache shelves.

[0079] In accordance with the present disclosure sorting, with the lift, the picked goods items containers into a predetermined order on the picked goods items container cache shelves.Aty. Docket No. 1127P017282-WO (PCT)

[0080] In accordance with the present disclosure resequencing, with the lift, the picked goods items containers and effecting a change in the ordered sequence of the picked goods items containers held at the picked goods items container cache shelves.

[0081] It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the present disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances that fall within the scope of any claims appended hereto. Further, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be advantageously used, such a combination remaining within the scope of the present disclosure.

[0082] What is claimed is:

Claims

Aty. Docket No. 1127P017282-WO (PCT)CLAIMS1. A retail fulfillment system for order filling of goods items, the system comprising: a multilevel container storage array, each level of which has a transport area and a storage area, the storage area including an array of storage shelves configured to hold thereon containers of at least one of the goods items, and the transport area being substantially continuous and arranged to communicably connect storage shelves of the array of storage shelves to each other, the transport area including picking aisles and a container transfer deck connecting the picking aisles; an autonomous guided container transport vehicle, distinct from the container transfer deck, located on each level of the multilevel storage array and configured to traverse the container transfer deck and picking aisles on each level and transport containers accessed to and from container storage locations on each of the storage shelves on each level of the multilevel storage array for at least one goods items order picking station; a lift communicably connecting the storage shelves of the array to a conveying output feeding picked goods items containers to an order fill output station, the lift having an end effector disposed to transfer containers to and from the lift in more than one direction, each direction describing a corresponding side of the lift; a putwall of more than one levels of picked goods items container cache shelves, at each level, adjacent to each corresponding side of the lift, each cache shelf being disposed to form a row of picked goods items container cache storage locations so that the autonomous guided container transport vehicle on each level communicates with cache storage locations in the row, and so that the end effector of the lift transfers a picked goods items container to and from each cache storage location of the putwall with at least one of the more than one different directions; andAty. Docket No. 1127P017282-WO (PCT) a controller configured to effect operation of the autonomous guided container transport vehicle between one or more of the container storage locations, and at least one picked goods items container cache storage shelf of the putwall, and of the lift transferring the picked goods items container from each cache storage location of the putwall to the conveying output feeding each goods items container from the putwall to the order fill output station.

2. The retail fulfillment system of claim 1, wherein the conveying output feeding each container is a common output from the putwall to each order fill output station.

3. The retail fulfillment system of claim 1, wherein the lift has more than one respective lifts arranged in series in the putwall, so that each cache storage location of the putwall is accessed by at least one of the respective lifts in at least one of the more than one directions.

4. The retail fulfillment system of claim 3, wherein each of the picked goods items container cache shelves are configured as one of a high usage cache or a low usage cache for holding respective high usage picked goods items containers and low usage picked goods items containers.

5. The retail fulfillment system of claim 3, wherein one of the directions describing a corresponding side of the lift is configured for accessing the high usage cache shelves and another direction is configured for accessing the low usage cache shelves.

6. The retail fulfillment system of claim 1, wherein the each picked goods items container cache shelf has a corresponding height.

7. The retail fulfillment system of claim 6, wherein the corresponding height of at least one picked goods items container cache shelf is different from other picked goods items container cache shelves.Aty. Docket No. 1127P017282-WO (PCT)8. The retail fulfillment system of claim 1, wherein the lift is configured to sort the picked goods items containers into a predetermined order on the picked goods items container cache shelves.

9. The retail fulfillment system of claim 1, wherein the lift is configured so as to resequence the picked goods items containers and effect a change in the ordered sequence of the picked goods items containers held at the picked goods items container cache shelves.

10. A method of fulfilling an order of goods items in a retail fulfillment system, the method comprising: providing a multilevel container storage array, each level of which has a transport area and a storage area, the storage area including an array of storage shelves for holding thereon containers of at least one of the goods items, and the transport area being substantially continuous and arranged to communicably connect storage shelves of the array of storage shelves to each other, the transport area including picking aisles and a container transfer deck connecting the picking aisles; providing an autonomous guided container transport vehicle, distinct from the container transfer deck, located on each level of the multilevel storage array for traversing the container transfer deck and picking aisles on each level and transporting containers accessed to and from container storage locations on each of the storage shelves on each level of the multilevel storage array for at least one goods items order picking station; providing a lift communicably connecting the storage shelves of the array to a conveying output feeding picked goods items containers to an order fill output station, the lift having an end effector disposed for transferring containers to and from the lift in more than one direction, each direction describing a corresponding side of the lift;Aty. Docket No. 1127P017282-WO (PCT) providing a putwall of more than one levels of picked goods items container cache shelves, at each level, adjacent to each corresponding side of the lift, each cache shelf being disposed to form a row of picked goods items container cache storage locations so that the autonomous guided container transport vehicle on each level communicates with cache storage locations in the row, and so that the end effector of the lift transfers a picked goods items container to and from each cache storage location of the putwall with at least one of the more than one different directions; and effecting, with a controller, operation of the autonomous guided container transport vehicle between one or more of the container storage locations, and at least one picked goods items container cache storage shelf of the putwall, and of the lift transferring the picked goods items container from each cache storage location of the putwall to the conveying output feeding each goods items container from the putwall to the order fill output station.

11. The method of claim 10, wherein the conveying output feeding each container is a common output from the putwall to each order fill output station.

12. The method of claim 10, wherein the lift has more than one respective lifts arranged in series in the putwall, so that each cache storage location of the putwall is accessed by at least one of the respective lifts in at least one of the more than one directions.

13. The method of claim 12, wherein each of the picked goods items container cache shelves are configured as one of a high usage cache or a low usage cache for holding respective high usage picked goods items containers and low usage picked goods items containers.

14. The method of claim 12, wherein one of the directions describing a corresponding side of the lift is configured for accessing the high usage cache shelves and another direction is configured for accessing the low usage cache shelves.Aty. Docket No. 1127P017282-WO (PCT)15. The method of claim 10, wherein the each picked goods items container cache shelf has a corresponding height.

16. The method of claim 15, wherein the corresponding height of at least one picked goods items container cache shelf is different from other picked goods items container cache shelves.

17. The method of claim 10, further comprising sorting, with the lift, the picked goods items containers into a predetermined order on the picked goods items container cache shelves.

18. The method of claim 10, further comprising resequencing, with the lift, the picked goods items containers and effecting a change in the ordered sequence of the picked goods items containers held at the picked goods items container cache shelves.

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