Process for batch picking in an automated storage and retrieval system

Abstract

A method (42) of batch picking of items in an automated storage and retrieval system, the automated storage and retrieval system comprising: A) a grid framework structure comprising a track system for guiding the movement of one or more load handling devices, the track system comprising a plurality of tracks arranged in a grid pattern and forming a plurality of grid cells, and a supporting framework structure comprising a plurality of storage columns arranged below the track system and arranged to accommodate a plurality of storage containers and a plurality of delivery containers; B) a batch picking system comprising a pick station, said pick station comprising a picking mechanism configured to pick at least one item from a storage container and a dispenser mechanism configured to receive the at least one item from the picking mechanism, said dispenser mechanism being moveable above the track system to dispense the at least one item to at least one of the plurality of delivery containers in their respective storage columns; the method comprising the steps of: i) consolidating (44) a plurality of orders into at least one batch of orders based on each order of the at least one batch of orders comprising an item having an attribute that is common to each order of the at least one batch of orders; ii) moving a storage container containing a plurality of the items having the common attribute to a position adjacent the picking mechanism such that the plurality of the items contained therein are accessible by the picking mechanism; iii) transferring, by the picking mechanism, at least one of the plurality of items to the dispenser mechanism; iv) dispensing (54), by the dispenser mechanism, at least one of the plurality of items to at least one of the plurality of delivery containers in their respective storage column that is inaccessible by the picking mechanism.

Description

[0001] Process for Batch Picking in an Automated Storage and Retrieval System

[0002] Field of the Invention

[0003] The present invention relates to the field of automated order fulfilment systems. In particular, the present invention relates to an improved system and method for batch picking in a fully or semi-automated storage and retrieval system.

[0004] Background

[0005] Various forms of both fully- and semi-automated order processing and fulfilment systems are known. They, and the various components they comprise, may take many forms.

[0006] In some forms of goods-to-man picking systems, for example, bins or other storage containers containing inventory and / or other items may be stored within, and retrieved from, a storage and retrieval system, in order to facilitate picking of items from the storage containers at picking stations. Pallet goods and / or other multi-packs of inbound items are separated and placed, individually or in groups corresponding to their stock keeping unit (SKU) into separate storage containers for storage in the storage and retrieval system.

[0007] Storage and retrieval systems typically comprise a three-dimensional storage grid framework 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. For the avoidance of doubt, the term “grid framework structure” is used to mean a three-dimensional structure within which the storage containers are stored, and 30 the terms “grid structure” and “grid” are used interchangeably to mean the two-dimensional structure in a substantially horizontal plane upon which the load handling devices operate.

[0008] 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 terms “bin”, “container”, “storage container” and “tote” are used interchangeably in this description to refer to the same object. The stacks 12 are arranged in a grid framework structure 14 in a warehousing or manufacturing environment. The grid framework structure 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.

[0009] The three-dimensional grid framework structure 14 comprises a supporting framework structure comprising a plurality of upright members or upright columns 16 that support a track system for guiding the movement of the load handling devices in lateral directions on the grid framework structure. The track system comprises horizontal members 18, 20 arranged in a grid pattern comprising a plurality of grid cells. 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 grid structure lying in a horizontal plane and 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 plurality of upright columns are arranged to form the plurality of storage columns for the storage containers to be stacked between the upright columns to guard against horizontal movement of the stacks 12 of storage containers 10, and be guided by the upright column in a vertical direction through the plurality of grid cells.

[0010] The track system further comprises a plurality of rails or tracks 22 at the top level of the grid framework structure and like the horizontal grid members 18, 20 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. The plurality of tracks can be integrated into the plurality of horizontal members such that the track system comprises a plurality of single body track members forming the track system or alternatively, the plurality of tracks and plurality of horizontal members are formed as separate bodies that are connected together.

[0011] As an alternative to the grid framework structure 14 supporting the 2D track system directly on a plurality of upright columns 16 as described with reference to Figure 1, in other examples the supporting framework structure supporting the 2D track system comprises a plurality of prefabricated modular panels arranged in a grid pattern, the detail of which is described briefly below and fully in the PCT application, WO2022034195A1, in the name of Ocado Innovation Ltd, and incorporated herein by reference. This grid framework structure described in WO2022034195A1 addresses the problem of time and cost to assemble by supporting the 2D track system on a supporting framework structure comprising a plurality of prefabricated modular panels arranged in a three dimensional grid pattern to define a plurality of grid cells. Each of the grid cells of the supporting framework structure is sized to support two or more grid cells of the 2D track system upon which the load handling devices operate. The grid framework structure is formed from fewer structural components yet still maintains the same structural integrity as the typical “stick-built” grid framework structure 14 described above, and is much faster and cheaper to build.

[0012] The prefabricated modular panels of the grid framework structure described above comprise upright columns 16. For example, a sub-group of the upright columns can be braced by one or more bracing members to form prefabricated panels or frames. For the purpose of the present invention, the plurality of upright columns 16 can also include the upright columns 16 in the prefabricated panels. The grid framework structure can comprise any appropriate supporting framework structure to support the grid, including upright columns 16 directly supporting the grid, and / or prefabricated panels and / or frames incorporating upright columns 16.

[0013] A known load handling device 30 shown in Figure 4 and 5 comprising 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 directional mechanism comprising 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.

[0014] The load handling device 30 is equipped with a lifting device (lifting mechanism) or crane mechanism driven by one or more motors 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 Figures 1 and 2. The grabber device comprises a plurality of grippers or gripper elements that are configured to grip a storage container when actuated by an actuator. Typically, the each of the grippers elements are configured to be received in one or more openings or depressions in the rim of the storage container. The gripper elements are moveable from a contracted position to be received in the opening or depression in the rim of the storage contain to an expanded position to engage with the rim of the storage container. Each of the gripper elements comprises a stop that engages with the rim when in the expanded position such that the storage container remains attached or connected to the lifting frame when the grabber device is lifted.

[0015] The wheels 34, 36 are arranged around the periphery of a cavity or recess, known as a container-receiving recess or container receiving space 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.

[0016] The container receiving space 40 may comprise a cavity or recess arranged within the vehicle body, e.g., as described in WO 2015 / 019055 (Ocado Innovation Limited). Alternatively, the vehicle body of the load handling device may comprise a cantilever as taught in WO2019 / 238702 (Autostore Technology AS) in which case the container receiving space is located below a cantilever of the load handing device. In this case, the grabber device is hoisted by a cantilever such that the grabber device is able to engage and lift a container from a stack into a container receiving space below the cantilever.

[0017] 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.

[0018] Although not shown in Figures 1-3, the load handling device 30 is powered during operation by an on-board rechargeable battery. Examples of rechargeable batteries are Lithium- Ion battery, Nickel-Cadmium battery, Nickel-Metal Hydride battery, Lithium-Ion Polymer battery, Thin Film battery and Smart battery Carbon Foam-based Lead Acid battery. The battery is recharged while the load handling device 30 is operative on the grid framework structure by a fixed charge station at the periphery of the grid framework. Alternatively, the rechargeable battery can be exchanged by a battery swap unit where a depleted rechargeable battery in the load handling device is replaced by a fresh, fully charged rechargeable battery. Upon receipt of a customer order, a load handling device operative to move on the tracks is instructed to pick up a storage container 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. Order picking stations can include various forms of systems for receiving storage containers of items retrieved by the storage and retrieval system so as to enable picking of items therefrom, for placement in delivery containers. Such systems typically includes various types and forms of conveyor or trolley based systems, wherein storage containers are loaded on conveyors or picking trolleys for transport to picking areas for automated and / or manual removal of items and placed in delivery containers, which are often of different type(s) than those used to store items, and which are provided by systems or other sources outside the storage system. A majority of the storage columns in the grid framework are used for the storage of containers in stacks. However, a grid framework structure normally has at least one storage column which is used not for storing storage containers, but which comprises a location where the container handling vehicles 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 or transferred out of or into the grid. Within the art, such a location is normally referred to as a “port” and the storage column in which the port is located may be referred to as a “delivery or port column”. The storage grids comprise two delivery columns. A first delivery column may for example comprise a dedicated drop-off port where the container handling vehicles or load handling vehicles can drop off storage containers to be transported through the delivery column and further to an access or a transfer station, and a second delivery 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 delivery column from an access or a transfer station. Storage containers in storage in the grid framework structure are typically fed to the order pick station via the port in the track system.

[0019] Orders assembled for delivery frequently comprise multiple delivery containers. Individual delivery containers, once they have been suitably filled with picked items, are typically set aside in separate order sortation or handling systems until all required delivery containers for an order or a whole delivery vehicle are ready. At that time the multiple containers required to fill the order are assembled and provided to a dispatch facility for loading or delivery.

[0020] Empty delivery containers may be returned, following delivery, to the sorting or dispatch area and fed back into the separate order sortation and handling system for re-use. In other embodiments, delivery containers may be in the form of cartons, which are not returned.

[0021] W02014 / 103126 (Ocado Innovation Limited) teaches a system and method for order processing where a delivery container may be placed inside a storage container to form a storage container combination. The upper edges of the delivery containers do not protrude above the upper edges of the storage containers, when placed therein. This allows the storage container combination to be stored within the grid framework structure. One or more delivery containers can be placed inside storage containers at the dispatch facility or between the dispatch facility and the storage and retrieval system. One or more shopping or other bags may be placed within the delivery containers; and the resulting storage container combination can be placed within the grid framework structure until needed at an order picking station. At an order picking station, delivery container(s) within a combination may be stocked with items picked from the same or different storage containers. When all delivery container(s) associated with an order have been appropriately filled, the storage combination is retrieved by the storage and retrieval system, where it is stored until the appropriate time when it is required for fulfilling an order, at which stage the storage combination is transferred to a dispatch facility. At the dispatch facility, the filled delivery containers are removed from its combination(s) and loaded or otherwise processed for delivery. W02014 / 103126 (Ocado Innovation Limited) teaches an apparatus to place delivery containers into storage containers with the help of the load handling devices. Here, bagged, delivery containers can arrive by conveyor to a transfer station. Storage containers can be deposited by the load handling devices onto the transfer stations and then moved by conveyor to a merge station conveyor. A transfer mechanism lifts the delivery container and moves it over the merge station conveyor. The merge station conveyor with the empty storage container can then be elevated by a lifting mechanism and the delivery container released from the transfer mechanism. The combined delivery and storage containers can now be transferred from the merge station conveyor onto a conveyor and on to a pick-up station. From the pick-up stations, the combined delivery and storage containers can be retrieved by the load handling devices and taken to an order picking station.

[0022] However, the efficiency and thus, the rate by which the delivery containers are suitably filled with picked items when fulfilling customer orders is very much dependent on the time taken to retrieve a target storage container and deliver the storage container to the order pick station. This typically involves instructing a load handling device operative on the grid framework structure to retrieve the storage container from a stack of storage containers in a storage column and subsequently transporting the storage container to the order picking station via the delivery port column. If it is necessary to retrieve a container (“target container”) that is not located on the top of a stack, then the overlying containers (“non-target containers”) must first be moved to allow access to the target containers. This is achieved in an operation referred to hereafter as “digging”. During a digging operation, one of the load handling devices sequentially lifts each non-target container from the stack containing the target container and places it in a vacant position within another stack. This process is repeated each time a different item is requested to fulfil a customer order. The time taken to retrieve a storage container from the grid framework structure and deliver the storage container to the order pick station represents a significant proportion of the time taken to fulfil a customer order. This time is exacerbated when fulfilling a large number of individual customer orders in multiple delivery containers as this will require multiple trips to and from the grid framework structure and the order pick station. Moreover, such repeated requests for storage containers from the grid framework structure results in congestion at the port as the load handling devices are forced wait for a port column to be free before being able to deliver a storage container containing a particular SKU to the order pick station. Considering that a typical storage and retrieval system is commissioned to fulfil hundreds or even thousands of customer orders daily, the time taken to transfer items from one or more storage containers to the delivery containers represent a significant bottleneck when fulfilling customer orders. A process is thus required to increase the rate at which customer orders are fulfilled.

[0023] Summary of the Invention

[0024] In the present disclosure, a plurality of individual customer orders are grouped together into at least one batch of individual customer orders based on each of the plurality of customer orders having at least one item having an attribute that is common to each of the plurality of customer orders and requesting a storage container storing the at least one item to a position where the storage container can be accessible by a picking mechanism. The common attribute could be items having the same stock control unit (SKU) and / or have the same barcode and / or simply the same type of item. Usually this would involve transporting the storage container comprising the plurality of items via a port column to an inventory handling station outside of the grid framework structure where the items are picked and transferred to a batch of delivery containers. A batch could comprise two or more individual customer orders which are fulfilled in two or more delivery containers. To fulfil a batch of customer orders, it is necessary that the batch of delivery containers are transported to the inventory handling station together with the relevant storage containers comprising the required SKUs (Stock Keeping Unit) to fulfil the customer orders. Transferring an item to the batch of delivery containers to fulfil a customer order can be performed by a manual picker or automatically by a robotic arm mounted to the inventory handling station. Once the customer order has been fulfilled, the batch of delivery containers are transported into storage in the grid framework structure until they are ready for dispatch. To enable the delivery containers to be handled by the robotic load handling devices operative on the grid framework structure, the delivery container is placed in a storage container to form a storage container combination as discussed above.

[0025] Typically, when a batch of customer orders are fulfilled at an inventory handling station outside of the grid framework structure in a batch of delivery containers, multiple robotic load handling devices operative on the grid framework structure would need to be instructed to retrieve the batch of delivery containers from the inventory handling station via a port column and locate one or more grid cells in the grid framework structure to subsequently store the batch of delivery containers in the grid framework structure. However, the time taken to transfer the picked items to the batch of delivery containers at the inventory handling station and subsequently, transporting the delivery containers by multiple load handling devices into storage in the grid framework structure not only represent a delay in sorting the customer orders into the grid framework structure but takes away multiple load handling devices from performing useful duties on the grid framework structure to fulfil additional customer orders. In a worst-case scenario, the request to use multiple robotic load handling devices to retrieve the batch of delivery containers from the inventory handling station may result in congestion at the port columns as the multiple load handling devices wait to pick up the delivery container (or storage container combination).

[0026] The present invention has mitigated the above problem by fulfilling a batch of individual customer orders in-situ whilst the delivery containers are still in storage in the grid framework structure. In other words, there is no need to transport the delivery containers to the inventory handling station outside of the grid framework structure when fulfilling customer orders saving both space at the inventory handling station and time to fulfil the customer orders. The present disclosure allows individual customer orders to be fulfilled in-situ whilst a batch of the plurality of delivery containers are in storage in the grid framework structure, i.e., in their respective storage columns. This removes the need to transport the delivery containers to the inventory handling station and then, subsequently storing the delivery containers in the grid framework structure once their customer orders have been fulfilled prior to dispatch.

[0027] More specifically, the present invention provides a dispenser mechanism for an automated storage and retrieval system. The automated storage and retrieval system comprises a track system for guiding the movement of one or more load handling devices, the track system comprising a plurality of tracks arranged in a grid pattern and forming a plurality of grid cells, and a supporting framework structure comprising a plurality of storage columns, the plurality of storage columns being arranged below the track system and arranged to accommodate a plurality of storage containers and a plurality of delivery containers. The dispenser mechanism comprises a body comprising sidewalls and a bottom wall with an open top end for receiving the one or more items, at least a portion of the bottom wall having at least one opening extending through the at least portion of the bottom wall of the body. A trap door for closing the at least one opening. A drive mechanism configured to drive the trap door between a closed position for containing one or more items within the dispenser mechanism and an open position to cause the one or more items to be dispensed from the dispenser mechanism from the at least one opening. The operation of the trap door is controlled by a dispenser controller or controller. The dispenser controller comprising one or more processors and memory storing instructions that when executed by the one or more processors is operable to control the movement of the trap door between the closed position and the open position. The dispenser controller and the drive mechanism forming an electrical load. The dispenser mechanism comprises a rechargeable power source for providing power to the electrical load. The body comprises a charge receiving interface electrically coupled to the rechargeable power source and a communication interface. The charge receiving interface being configured to electrically or magnetically couple with a charge providing interface and the dispenser controller is configured to receive instructions to control the movement of the trap door between the closed position and the open position through receiving instructions via the communication interface.

[0028] Optionally, the trap door comprises at least one door leaf rotatably mounted to the body of the dispenser mechanism by a hinge mechanism. The drive mechanism is coupled to the hinge mechanism for driving the at least one door leaf between a closed position for containing one or more items within the dispenser mechanism and an open position to cause the one or more items to be dispensed from the dispenser mechanism from the at least one opening. The hinge mechanism is coupled to the drive mechanism by a gear mechanism operable to control the movement of the at least one door leaf between the closed position and the open position. A rechargeable power source provides power to the drive mechanism.

[0029] By coupling the hinge mechanism to the drive mechanism by a gear mechanism enables the movement of the at least one door leaf of the trap door to be precisely controlled between the closed and open positions. The gear mechanism also allows passive locking of the at least one door leaf of the trap door in different angular orientations between the closed and open configuration. Orientating the at least one door leaf at different angles enables the trap door to control the release of the at least one item from the dispenser mechanism. Different angles of the at least one door leaf of the trap door relative to the vertical controls the rate of descent of the item as a result of friction between the item and the surface of the at least one door. The gear mechanism may optionally comprise a worm gear engageable with a worm wheel such that rotation of the worm gear by the drive mechanism drives rotation of the worm wheel to rotate the at least one door leaf of the trap door between the open and closed positions. The advantage of the worm gear to control the opening of the at least one door leaf is the ability to self-lock the at least one door leaf at different angular orientations relative to the horizontal when supporting a load on the at least one door leaf and / or having a high gear ratio.

[0030] To control the angular orientation of the at least one door leaf, optionally, the dispenser mechanism further comprises a sensor system configured to sense the position of the at least one door leaf between the closed position and the open position, and wherein the dispenser controller is configured to control the gear mechanism to control the orientation of the at least one door leaf of the trap door between the closed position and the open position in response to one or more signals from the sensor system. Optionally, the sensor system comprises a position sensor configured to sense the position of the at least one door leaf at the closed position and / or at the open position and a rotary encoder configured to determine the rotation of the at least one door leaf. The position sensor is calibrated to determine the positions of the at least one door when at the closed position and at the open position. Such positions can be considered end positions of the at least one door, i.e., a reference position. Signals from the rotary encoder is an indication of the angular rotation of the at least door leaf between the end positions. Optionally, the closed position of the at least one door leaf is when the at least one door is at a substantially horizontal position and the open position is when the at least one door leaf is at a substantial vertical orientation. Optionally, the position sensor comprises a hall effect sensor.

[0031] To conceal the gear mechanism and the drive mechanism into the body of the dispensing mechanism, optionally, the at least one door leaf of the trap door is rotatably mounted to at least one of the sidewalls of the body of the dispensing mechanism.

[0032] In certain cases, the rechargeable power source may comprise a capacitor, e.g., a supercapacitor. The capacitor is advantageous in its ability to charge faster and able to hold enough charge to power the drive mechanism to operate the at least one door leaf between the closed and open positions.

[0033] In the case where dispenser container is instructed to distribute at least one of the plurality of common items to each of the delivery containers in storage in the grid framework structure, optionally, the at least one door leaf may optionally comprise a plurality of door leaves, each of the plurality of door leaves being independently moveable relative to each other between the closed position and the open position to open at least a portion of the bottom wall of the dispenser mechanism such that at least one of the plurality of the items is deposited into the at least one of the plurality of delivery containers.

[0034] Having each of the plurality of door leaves that are independently moveable relative to each other between closed and open positions to release an item supported by at least one of the plurality of door leaves enable a plurality of customer orders to be fulfilled in a single operation of the load handling device on the track system rather than repetitive movements between the picking mechanism and each of the batch of the delivery containers in storage. For example, to fulfil a plurality of customer orders with one or more of the items, the dispenser container can be moved above each of the batch of delivery containers in the grid framework structure in succession and at each successive movement of the dispenser container above each of the batch of delivery containers, moving at least one of the plurality of door leaves to the open position to deposit one or more of the plurality of items into a respective delivery container below to fulfil a customer order.

[0035] In certain cases, the at least one door leaf of the trap door may be rotatably mounted to at least one of the sidewalls of the body of the dispensing mechanism.

[0036] The charge receiving interface may optionally comprise at least two charge receiving pads connectable to at least two charge providing pads of the charge providing interface.

[0037] Alternatively, the charge receiving interface may comprise a wireless charging transmitter coil for inductively coupling with the wireless charging receiver coil of the charge providing interface.

[0038] The dispenser mechanism may optionally be configured such that the sidewalls and the bottom wall are arranged to form a dispenser container with the open top end for receiving the one or more items within the dispenser container. The dispenser container may comprise a rim portion extending around at least a portion of the periphery of the open end of the dispenser container, the rim portion comprising one or more openings or depressions for engagement with a grabber device of a load handling device. Despite the need to instruct a load handling device operable on the grid framework structure to pick up the dispenser container, the advantage of the dispenser container is that it provides a relatively low-cost mechanism to fulfil a batch of customer orders in-situ on the grid framework structure.

[0039] The dispenser mechanism may optionally comprise a robotic dispenser device comprising a driving assembly configured to move on the track system and a body having an opening extending to the track system, the opening being closable by a trap door comprising at least one door leaf moveable between an open and a closed position. Instead of a dedicated dispenser container, the features of the dispenser container can be incorporated into a load handling device to define a robotic dispenser device. Like the load handling device, the robotic dispenser device comprises a driving assembly to enable the robotic dispenser device to move on the track system and a body having an opening extending to the track system. The opening of the body is closeable by a trap door that is moveable between a closed position to support on or more items within the body of the robotic dispenser device and an open position to allow the one or more items to be released from the body of the robotic dispenser device. Since the opening extends to the track system, the open position of the trap door allows one or more items to be deposit into an opening of a grid cell.

[0040] The present disclosure further provides an automated storage and retrieval system for batch picking of items. The automated storage and retrieval system comprising a grid framework structure comprising a track system for guiding the movement of one or more load handling devices, the track system comprising a plurality of tracks arranged in a grid pattern and forming a plurality of grid cells, and a supporting framework structure comprising a plurality of storage columns arranged below the track system and arranged to accommodate a plurality of storage containers and a plurality of delivery containers. The automated storage and retrieval system further comprises a load handling device comprising a controller configured to control the operation of the load handling device on the track system in response to receiving one or more signals from a master controller that is remote from the controller.

[0041] The automated storage and retrieval system includes a pick station having a picking mechanism configured to extract one or more items from a storage container, and a dispenser mechanism as described above that is configured to receive the one or more items from the picking mechanism. The dispenser mechanism is transportable above the track system by the load handling device, which delivers the items to one or more delivery containers located within respective storage columns, in accordance with instructions received from the load handling device’s controller.

[0042] Typically, the instructions issued by the master controller are complex and require substantial computational resources to translate into suitable control signals for operating the load handling device. Consequently, the load handling device is equipped with a high-performance processor capable of handling such processing demands. By contrast, the dispenser mechanism employs a lower-power controller — such as a microcontroller — to minimize weight and cost. However, a low-power controller lacks the processing capability to directly interpret and execute complex instructions received from the master controller.

[0043] In the present disclosure, the controller of the load handling device is configured to process and convert the complex signals received from the master controller into a simplified format that can be readily interpreted by the dispenser controller. This arrangement enables the dispenser controller to function effectively while consuming less power and maintaining a lower overall cost. The automated storage and retrieval system may optionally include a picking mechanism mounted to the track system such that a first grid cell and a second grid cell of the track system are accessible by the picking mechanism, e.g., a robotic arm.

[0044] In addition to, or as an alternative to, transferring one or more items to either the dispenser container or the robotic dispenser device via the picking mechanism on the grid framework structure, the present invention also contemplates that the dispenser container may be preloaded with a plurality of items — corresponding to a batch of individual customer orders — outside of the grid framework structure. Once loaded, the dispenser container can be introduced onto the track system to distribute the batch of items into a plurality of delivery containers positioned within respective grid cells.

[0045] This arrangement allows the picking operation to be performed manually by an operator or automatically by a robotic arm external to the grid framework. In some instances, certain items required to fulfil customer orders may not be easily handled by a robotic arm mounted on the track system, for example due to the nature of the arm’s end effector or the geometry of the item itself. Furthermore, dispensing items from the dispenser container is facilitated by the presence of the trap door mechanism, which allows for more efficient item release.

[0046] Accordingly, storage containers holding items that share a common attribute can be manually selected at a pick station and transferred into the dispenser container outside of the grid framework structure. The dispenser container can then be engaged by a load handling device operating on the track system — typically via at least one port column — and used to deposit one or more of the preloaded items into each of the delivery containers stored within the grid structure..

[0047] Optionally, the load handling device comprises a) a driving assembly configured to move the load handling device on the track system; b) a grabber device configured to releasably hold a storage container from above; and c) a lifting assembly configured to raise and lower the grabber device into and out of the supporting framework structure via the grid cells; wherein the controller is configured to control the operation of the load handling device on the track system by controlling the operation of the driving assembly, the grabber device and the lifting assembly. Optionally, the grid framework structure may further comprise at least one port column, the at least one port column extending downwardly from a grid cell to the pick station through which the load handling device can drop off and pick up storage containers from the pick station. The pick station may comprise a conveyor system comprising a drop-off zone for receiving the at least one of the plurality of storage containers via the at least one port column, a pick-up zone for picking-up the at least one of the plurality of storage containers from the conveyor system via the at least one port column and an access zone for accessing the contents of the at least one of the plurality of containers on the conveyor system. The conveyor system may be arranged to transport the at least one of the plurality of storage containers from the drop-off zone to the pick-up zone via the access zone. An example of pick station arranged to receive containers thought a port column is described in WO2021 / 239559 (Ocado Innovation Ltd), the content of which are incorporated herein by reference.

[0048] To drop off and pick-up one or more storage containers from the pick station, optionally, the at least port column comprises a drop-off column and a pick-up column, said drop-off column cooperates with the drop-off zone for receiving one or more of the plurality of storage containers via the drop-off column and said pick-up column cooperates with the pick-up zone for picking up one or more storage containers from the pick-up zone towards the track system via the pick-up column. Optionally, the drop-off column and the pick-up column can be separate port columns or a single port column.

[0049] The conveyor system may further comprise a dispenser drop-off zone for receiving the dispenser mechanism via the at least one port column, a dispenser pick-up zone for picking up the dispenser mechanism from the conveyor system via the at least one port column and a dispenser access zone for accessing the dispenser mechanism on the conveyor system. The conveyor system may be arranged to transport the dispenser mechanism from the dispenser drop-off zone to the dispenser pick-up zone via the dispenser access zone.

[0050] Optionally, the conveyor system can be arranged such that the dispenser access zone is adjacent the access zone such that, in use, the storage container and the dispenser container at their respective access zone and the dispenser access zone are accessible by the picking mechanism.

[0051] To drop off and pick-up the dispenser container between the grid framework structure and the picking mechanism, optionally, the at least one port column comprises a dispenser drop-off column and a dispenser pick-up column, said dispenser drop-off column cooperates with the dispenser drop-off zone for receiving the dispenser mechanism via the dispenser drop-off column and said dispenser pick-up column cooperates with the dispenser pick-up zone for picking up the dispenser container from the dispenser pick-up zone towards the track system via the dispenser pick-up column Optionally, the dispenser drop-off column and the dispenser pick-up column can be separate port columns or a single port column.

[0052] A method of batch picking of items in an automated storage and retrieval system as described above is also described. The method comprises (i) consolidating a plurality of orders into at least one batch of orders based on each order of the at least one batch of orders comprising an item having an attribute that is common to each order of the at least one batch of orders. In step (ii), a storage container containing a plurality of the items having the common attribute is moved to a position adjacent the picking mechanism such that the plurality of the items contained therein are accessible by the picking mechanism. In step (iii), the picking mechanism transfers at least one of the plurality of items to the dispenser mechanism. In step (iv), the dispenser mechanism dispenses at least one of the plurality of items to at least one of the plurality of delivery containers in their respective storage column that is inaccessible by the picking mechanism.

[0053] The attribute of the item that is common to each of the plurality of orders may optionally be a stock control unit (SKU) and / or a barcode.

[0054] The dispensing mechanism can comprise a first and second dispensing mechanisms such that the first dispensing mechanism can dispense one or more items to the second dispensing mechanism. The second dispensing mechanism can act as a buffer to hold the items until they are ultimately ready to be dispensed into the delivery containers.

[0055] The plurality of delivery containers and the plurality of storage containers may be arranged in one or more stacks of containers. The method may further comprise determining whether one or more of the plurality of storage containers overlay one or more of the plurality of delivery containers in a given stack of containers, and if one or more of the plurality of storage containers overlay one or more of the delivery containers in the given stack, removing the one or more of the overlaying storage containers from the given stack to expose the delivery container to the track system.

[0056] The method may further comprise repeating the transferring and dispensing steps to a batch of the plurality of the delivery containers such that each of the batch of the plurality of delivery containers comprises at least one of the plurality of the items. The method may optionally include instructing the picking mechanism to transfer the plurality of items to the dispenser mechanism, and instructing the dispenser mechanism to deposit at least one of the plurality of items into each of a batch of the plurality of delivery containers in their respective storage columns in succession until each of the batch of the plurality of delivery containers comprises at least one of the plurality of items.

[0057] There are two ways according to the present invention by which a batch of individual customer orders can be fulfilled. In one example, the steps of transferring an item, by the picking mechanism, to the dispenser mechanism in step (iii) and subsequently depositing, by the dispenser mechanism, the item into a delivery container in a storage column in step (iv) are repeated until each delivery container in a batch of the plurality of delivery containers comprises at least one of the plurality of the items. In another example, the picking mechanism in step (iii) is instructed to transfer the plurality of the items to the dispenser mechanism (instead of at least one of the items), and the dispenser mechanism in step (iv) is instructed to deposit at least one of the plurality of the items into each of a batch of the plurality of delivery containers in their respective storage columns in succession until each of the batch of the plurality of delivery containers comprises at least one of the plurality of items. The present invention provides a dispenser mechanism that is able to receive a plurality of the items having a common attribute and transfer the plurality of the items to the batch of delivery containers in-situ in the grid framework structure regardless where in the grid framework structure the batch of the delivery containers are stored, i.e., if they are further away from the picking mechanism.

[0058] For the dispenser mechanism to deposit at least one of the items to each of the batch of delivery containers, the dispenser mechanism can be configured to deposit at least one the items to each of the batch of the plurality of delivery containers in succession. The batch of the delivery containers can be distributed in the grid framework structure that are inaccessible to the picking mechanism. To fulfil a batch of customer orders into the batch of delivery containers, typically, the delivery containers and the storage container are grouped together in close proximity with the picking mechanism in order to transfer the items from the storage container to the batch of the delivery containers. The present method removes the need to group the delivery containers and the storage container storing the items to be picked together. In the present disclosure, the dispenser mechanism is configured to receive and hold the plurality of the items transferred from the picking mechanism. Since the customer orders can be fulfilled into the batch of the delivery containers in-situ in the grid framework structure, optionally, the picking mechanism is mounted to the track system such that a first grid cell and a second grid cell of the track system are accessible by the picking mechanism and wherein step (ii) comprises the step of instructing the load handling device to deliver the storage container containing a plurality of the items to the first grid cell of the track system.

[0059] As the first and second grid cells are accessible by the picking mechanism, to transfer the plurality of the items from the storage container in the first grid cell to the dispenser container, optionally, step (iii) further comprises the step of instructing the load handling device operable on the track system to deliver the dispenser container to the second grid cell of the track system.

[0060] To deposit the plurality of the items to each of the batch of the plurality of delivery containers in their respective grid cells that are inaccessible by the picking mechanism, optionally, step (iv) further comprises the steps of instructing the load handling device operable on the track system: a) to pick up the dispenser container comprising at least one of the plurality of the common items from the second grid cell; and b) move the dispenser container above the at least one of the plurality of delivery containers such that moving the at least one door leaf of the bottom wall to the open position deposits the at least one of the plurality of the items into the at least one of the plurality of delivery containers.

[0061] In the example, where the picking mechanism transfers the plurality of the items to the dispenser container, then step (iv) further comprises the steps of instructing the load handling device operable on the track system: a) to pick up the dispenser container comprising the plurality of the items from the second grid cell; and b) move the dispenser container carrying the plurality of the items above each of the batch of the plurality of delivery containers in succession; wherein at each successive movement of the load handling device above each of the batch of the plurality of delivery containers, moving the at least portion of the bottom wall to the open position to deposit at least one of the plurality of items into a respective delivery container until each of the batch of the plurality of delivery containers comprises at least one of the plurality of the items.

[0062] The distribution of the plurality of the items to the batch of the delivery containers in-situ in the grid framework structure by the robotic dispenser device to fulfil a batch of customer orders is the same when using the dispenser container discussed above, namely the picking mechanism is mounted to the track system such that a first grid cell and a second grid cell of the track system are accessible by the picking mechanism and wherein step (iii) comprises the steps of: a) instructing the transfer device to move to the second grid cell such that the opening of the robotic transfer device is accessible by the picking mechanism; b) operating the picking mechanism to transfer at least one of the plurality of common items from the storage container into the opening of the robotic transfer device.

[0063] Thus, step (iv) further comprises the steps of instructing the robotic dispenser device to move across the track system to a position above the at least one of the plurality of delivery containers such that moving the trap door to the open position dispenses the at least one of the plurality of items into the at least one of the plurality of delivery containers.

[0064] Brief Description of the Drawings

[0065] 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:

[0066] Figure 1 is a schematic diagram of a grid framework structure according to a known system,

[0067] Figure 2 is a schematic diagram of a top-down view showing a stack of bins arranged within the framework structure of Figure 1.

[0068] Figure 3 is a schematic diagram of a system of a known load handling device operating on the grid framework structure.

[0069] Figure 4 is a schematic perspective view of the load handling device showing the lifting device gripping a container from above.

[0070] 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.

[0071] Figure 6 is a flowchart illustrating the processing steps to batch pick a plurality of customer orders according to the present disclosure.

[0072] Figure 7 is a schematic perspective view of a dispenser container comprising a trap door according to an example of the present invention.

[0073] Figure 8 is a schematic perspective cut away view of the transfer container shown in Figure 7 showing the release of an item from the transfer container. Figure 9 is a block diagram illustrating the main auxiliary components of the dispenser container.

[0074] Figure 10 is a transparent illustration of the hinge mechanism for opening and closing the trap door according to the present disclosure.

[0075] Figures 11 (a to d) are schematic illustrations of the hinge mechanism used to operate the trap door of the dispenser container shown in Figures 7 and 12(a and b) where (a and b) show the hinge mechanism orientating the trap door in a closed position; and (c and d) show the hinge mechanism orientating the trap door in an open position.

[0076] Figures 1 l(e and f) are schematic illustrations of the sensor system in cooperation with the hinge mechanism to monitor the angular orientation of the trap door; where (e) show the sensor system recording the trap door in the closed position; and (f) shown the sensor system recording the trap door in the open position.

[0077] Figures 12(a and b) is an illustration of the delivery container, where (a) shows carrier or shopping bags arranged and supported by the rim of the delivery container; and (b) shown the storage container combination.

[0078] Figure 13 are schematic perspective views of dispenser container comprising a plurality independently moveable door leaves, where (a) show the dispenser container moving a single door leaf to the open position; and (b) show the dispenser container moving all of the door leaves to the open position.

[0079] Figure 14 is an illustration of the door leaf comprising a raised profile with diverging portions on the underside of the door leaf that are configured to interact with the opening of a carrier or shopping bag. Figure 15 is an illustration of the raised profile of the door leaf shown in Figure 13 interacting with the shopping bag to prise open the shopping bag.

[0080] Figure 16 is an illustration of a robotic dispenser device comprising a trap door used for batch picking according to the present disclosure.

[0081] Figure 17 is a schematic depiction of a robotic arm mounted to the track system for transferring items from a storage container in a first grid cell to the dispenser container shown in Figure 7 and 12(a and b) in a second grid cell according to the present disclosure.

[0082] Figure 18 is a schematic illustration of a robotic load handling operative on the track system carrying the dispenser container shown in Figures 7, 8 and 12(a and b) and depositing an item into a delivery container in storage in the grid framework structure.

[0083] Figure 19 is a schematic illustration of a robotic arm mounted to a grid cell of the track system transferring one or more items from a storage container in a first grid cell to the robotic dispenser device shown in Figure 15 in the second grid cell.

[0084] Figure 20 is a schematic illustration showing the robotic dispenser device releasing an item into a delivery container in-situ in the grid framework structure.

[0085] Figure 21 is schematic depiction of an overhead view of grid framework structure showing the arrangement of the grid cells reserved for the storage container and the dispenser mechanism at the pick station.

[0086] Figure 22 is a flowchart illustrating the processing steps to batch pick a plurality of customer orders according to a second example of the present disclosure. Figures 23(a and b) are schematic perspective views of the pick station outside of the grid framework structure and in communication with the grid framework via one or more port columns.

[0087] Figure 24 is a flowchart illustrating the processing steps to batch pick a plurality of customer orders according to a third example of the present disclosure.

[0088] Figure 25 is a schematic illustration showing the electrical and / or communication interfaces at the rim of the dispenser container. Figure 26 is a schematic illustration showing the electrical and / or communication interface between the grabber device with the dispenser container when the grabber device engages with the dispenser container.

[0089] Figure 27 is a block diagram illustrating the interaction between the load handling device and the dispenser container.

[0090] Detailed Description

[0091] 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 track system, Z=2 is the second layer below the track 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.

[0092] To pick an order comprising different items, it is often necessary to retrieve items from multiple target storage containers. Such storage containers can be retrieved from the storage and retrieval system and brought to a pick station outside of the grid framework structure via one or more port columns. An example of such a pick station is detailed in WO 2021 / 239559 (Ocado Innovation Ltd), the detail of which is incorporated herein by reference. Items picked from the storage containers are placed into delivery containers. One or more shopping or other bags may be additionally placed within the delivery container. Individual delivery containers, once they have been suitably filled with picked items, are typically set aside in separate order sortation or handling systems until all required delivery containers for an order or a whole delivery vehicle are ready. At that time, the multiple delivery containers required to fill the order are assembled and provided to a dispatch facility for loading or delivery. Empty delivery containers may be returned, following delivery, to the sorting or dispatch area and fed back into the separate order sortation and handling system for re-use.

[0093] Empty or filled delivery containers are generally stored in the grid framework structure until required for fulfilling one or more customer orders at the pick station or dispatch at the dispatch facility. To enable the delivery containers 90 to be stored in the grid framework structure, typically, the delivery container is placed inside the storage container to define a storage container combination 93 (see Figure 12). One or more delivery containers 90 can be placed inside storage containers at the dispatch facility or between the dispatch facility and the storage and retrieval system.

[0094] To fulfil one or more customer orders, one or more robotic load handling devices operable on the track system are instructed to retrieve one or more storage containers containing the correct SKU type to fulfil the one or more customer orders together with one or more delivery containers 90 used for dispatch and transport both the one or more storage containers and delivery containers to a pick station outside of the grid framework structure, typically below the grid framework structure. At the order picking station, the delivery container(s) may be stocked with items picked from the same or different storage containers. When all delivery container(s) associated with an order have been appropriately filled, the storage container combination 93 is retrieved by a robotic load handling device, where it is stored until the appropriate time when it is required for fulfilling an order, at which stage the storage combination is transferred to a dispatch facility. At the dispatch facility, the filled delivery containers are removed from its combination(s) and loaded or otherwise processed for delivery.

[0095] To cater for a large number of customer orders in a given day, a plurality of pick stations are distributed around the grid framework structure, typically, around the periphery of the grid framework structure. Since access to the pick station is via one or more port columns, there is a tendency that the area around the port columns become congested as one or more robotic load handling devices wait to deliver the storage containers and the delivery containers to the pick stations. In some instances, repeated travels of the load handling devices are required to retrieve frequently requested items to the pick station throughout a given day to fulfil a plurality of customer orders into delivery containers. Such frequently requested items typically include convenience or staple common everyday items having a relatively short sell buy date, e.g., milk, dairy products etc, and typically, involve requiring the same storage container or bin or SKU to be presented at the pick station repeatedly.

[0096] Various control systems or controllers can be used to mitigate congestion at the port columns. These include the provision of a warehouse management system that monitors the time a storage container is at a pick station and if it exceeds a predetermined threshold, return the storage container back into the grid framework structure. Other provisions include the provision of a transfer system positioned between the storage and retrieval system and the pick station. The transfer system comprises a transfer station and conveyance means linking the transfer station to the storage side of the pick station such that a portion of items to be picked in to delivery containers at the pick station are supplied to the pick station by the conveyance means. For example, the conveyance means can comprise automatic guided vehicles (AGV) for transporting frequently requested items to the pick station; the detail of which are described in WO2019243549 (Ocado Innovation Ltd).

[0097] In all cases, it is necessary to deliver both the storage containers and the delivery containers to the pick station. The present invention has overcome the above problem by fulfilling at least a portion of the customer orders in-situ in the grid framework structure avoiding the need to transport the delivery containers to the pick station outside of the grid framework structure. Examples of the present disclosure are directed to systems and methods that is configured for batch picking in which a group of customer orders are consolidated based on the type of the inventory item required to fulfil the group of customer orders. For example, in batch picking this may involve consolidating the group of customer orders based on requiring the same or common type of item, e.g., same SKU or barcode. The present invention provides a warehouse management system that is configured to group as many customer orders into one or more batch of orders to enable batch picking in-situ in the grid framework structure, each of the batch of orders requiring the same or common items to be picked from a storage container. For batch picking, typically, a plurality of customer orders are grouped into one or more small batches of around 8 to 16 orders such that operators can fill all of the orders in the batch at the same time, working from a consolidated pick list. Since the customer orders are fulfilled in delivery containers, to batch pick a group of customer orders, a batch of delivery containers for batch picking are grouped together based on each of the orders in the batch requiring the same item type. The warehouse management system may include one or more memory devices storing instructions and one or more processors configured to execute the instructions. In some examples, the one or more processors are configured to receive an order comprising one or more items for batch picking.

[0098] To enable batch picking in-situ in the grid framework structure, the automated storage and retrieval system comprises a pick station comprising a picking mechanism that is configured to pick at least one item from a storage container and a dispenser mechanism configured to receive the at least one item from the picking mechanism. The storage container and the dispenser mechanism are positioned in the grid framework structure such that they are accessible by the picking mechanism, i.e., adjacent the picking mechanism. The dispenser mechanism is moveable above the track system to deliver at least one item to at least one of the plurality of delivery containers in the grid framework structure. To implement batch picking in-situ in the grid framework structure, the dispenser mechanism is configured to be moved to a plurality of storage locations (i.e., grid cell positions) in a single operation that have been identified by the warehouse management where a batch of the plurality of delivery containers for batch picking are stored in the grid framework structure. The batch of the plurality of delivery containers can comprise two or more delivery containers in storage in the grid framework structure. At each of the storage locations, the dispenser mechanism is configured to dispense or deposit one or more of the same or common items to a delivery container below. For the purpose of definition of the present invention, the term “common items” is construed to mean items that have an attribute that is common to each of the plurality or batch of customer orders. For example, the common attribute can be the same SKU (stock keeping unit) and / or the same identification, e.g., barcode or simply the same type of item in each of the plurality of customer orders.

[0099] To dispense an item into a delivery container in-situ in the grid framework structure, ideally the target delivery container that has been designated for batch picking is positioned at the uppermost layer immediately below the track system in a given stack of storage containers and / or storage combination, i.e., Z = 1, such that the mouth of the delivery container is exposed below the opening of the grid cell. For ease of explanation, the term “containers” can be broadly construed to capture both the storage container and the storage combination (delivery container and storage container). If one or more of the delivery containers for batch picking is not located in the uppermost layer in a given stack of containers, then the warehouse management system can instruct one or more load handling devices operative on the track system to move one or more of the overlying containers (“non-target containers”) to expose the delivery container (“target delivery container”) to the track system for batch picking, i.e. the mouth of the delivery container is exposed below the track system. This is achieved in an operation referred to hereafter as “digging”.

[0100] During a digging operation, one of the robotic load handling devices sequentially lifts each non-target container from the stack comprising the target delivery container and places it in a vacant position within another stack. Depending on the container depth, the delivery container can be left in its storage column or moved to the uppermost layer of another stack of containers. If the delivery container is not in the uppermost layer, then the delivery container is “dug” out of the stack of containers and moved to an uppermost layer of another stack of containers so that it is closer to the track system. Moreover, when relying on the item to fall under gravity from the dispenser mechanism into the delivery container through an opening in a grid cell, then the uppermost layer of a stack of containers should be such that the distance between the track system and the uppermost layer allows for an item to be dropped through the grid cell into the delivery container. The closer the delivery container is to the track system, the greater the certainty that an item dropped through a grid cell will fall into an exposed delivery container below. Moreover, for fragile items, e.g., glass or eggs, where the items have to be placed carefully to prevent them breaking, having the delivery containers closer to the opening of the grid cell is paramount to prevent the items from breaking when being released from the dispenser mechanism.

[0101] The process 42 for batch picking in-situ on the grid framework structure can be explained by the flowchart shown in Figure 6. The processing steps for batch picking are labelled A to G in Figure 6. However, the process to populate the dispensing mechanism with items for fulfilling a batch of individual customers orders is discussed further below with reference to Figures 22 in the case where the picking occurs on the grid framework structure or Figure 24 in the case where the picking occurs outside of the grid framework structure. Prior to batch picking, the warehouse management system collates a batch of customer orders on the basis that they have at least one item having an attribute that is common in each of the customer orders (herein referred to an “common item”) 44 and identifies a batch of the plurality of delivery containers (DT) in storage in the grid framework structure (GFS) for fulfilling the batch of customer orders with the at least one common item (herein referred to as “target delivery container”) 46. This may involve identifying the storage locations defined as the positions in the storage columns storing the target delivery containers. To deliver the at least one item having a common attribute, the warehouse management system determines whether the target delivery containers are in the uppermost layer in their respective stack or is exposed below the track system 48. If not, the warehouse management system instructs one or more load handling devices operative on the track system to move one or more of the identified delivery containers closer to the track system 50. This may involve digging the delivery container from amongst a stack of containers and repositioning the delivery container on to another stack of containers or removing one or more overlaying storage containers so allowing the delivery container to capture or receive an item dropped from above the track system via a grid cell. Once all of the identified delivery containers are exposed below the track system, the warehouse management system instructs the dispenser mechanism to move to a storage location above one of the identified delivery containers 52 and dispense one or more of the common items into the delivery container exposed below the track 54. The process of dispensing the at least one of the plurality of common items to the delivery container is repeated for each of the delivery containers in storage until all of the identified delivery containers comprises at least one of the common items 56. The dispenser mechanism is loaded with the plurality of common items for batch picking between the steps 44 and 46 in Figure 6. This can be carried in-situ on the grid framework structure by a robotic picking mechanism with reference to Figure 22 or outside of the grid framework structure with reference to Figure 24. Both loading steps are discussed further below.

[0102] The present disclosure provides different examples to fulfil a batch of customer orders whilst the delivery containers remain within the grid framework structure. In all of the different examples, the dispenser mechanism operating on the track system is configured to release one or more items into a delivery container below the track system via an opening in the grid cell. In a first example, the dispenser mechanism comprises a dispenser container 58 for dispensing one or more of the plurality of inventory items from the base of the dispenser container 58. In the particular example shown in Figures 7 and 8, the dispenser container 58 comprises a body 59 comprising opposing sidewalls 60 and a bottom wall 62 forming a box-like structure with an open end for receiving the one or more items within the box-like structure. At least a portion of the bottom wall is moveable between a closed position to contain an item 64 within the dispenser container 58 and an open position to expose an opening 66 in the bottom wall of the dispenser container for an inventory item 64 to be released from the dispenser container 58. The at least portion of the bottom wall can comprise a trap door 68 comprising at least one door leaf 70 that is openable between the closed and open positions. In the particular example shown in Figure 8, the least one door leaf 70 comprises two opposing door leaves 70, each of the two opposing door leaves can move independently or in synchronisation between the closed and open positions relative to the opposing sidewalls of the dispenser container. In the open position, the item 64 is released from the dispenser container 58 by falling under gravity as shown in Figure 8. However, it will be appreciated that other means to configure the dispenser container to dispense an item from the dispenser container is applicable in the present invention. For example, the opening in the base of the dispenser container may be a flap, two co-operating flaps, a rolling shutter or any other suitable opening or closing means capable of remote or autonomous. The dispenser container 58 is configured to be picked up and received within the container receiving space of a robotic load handling device operative on the track system. The container receiving space can be within the body of the robotic load handling device as discussed above or below a cantilever arm that extends laterally from the top of the body of the robotic load handling device as taught in WO2019 / 238702 (Autostore Technology AS). To enable the dispenser container to be carried by the robotic load handling device operable on the track system and be moved to a grid cell position above a target delivery container, the engagement features of the dispenser container resembles the engagement features 11 of the storage containers in the grid framework structure (see Figure 12). In the particular example of the present invention, the rim extending around the periphery of the open end of the box-like structure of the dispenser container comprises one or more openings or depressions (not shown) for receiving the gripper elements of the grabber device. It will be appreciated that other means for the grabber device of the robotic load handling device to engage with the dispenser container is applicable in the present invention. However, for simplicity, the engagement feature of the dispenser container is substantially the same as the engagement feature of the storage container to enable the grabber device of the robotic load handling device to engage with the dispenser container and the storage container. It will also be appreciated that the trap door can be retrofitted to an existing storage container, more specifically forming the bottom wall of an existing storage container. For example, the dispenser container can comprise an upper portion 94 and a lower portion 96. The upper portion comprises upper opposing sidewalls forming a tubular structure. The lower portion comprises lower opposing sidewalls and a bottom wall, said bottom wall comprises a trap door comprising at least one door leaf as discussed above and below. The lower portion can be retrofitted to the upper portion to form the dispenser container according to the present disclosure. Retrofitting the lower portion to the upper portion can comprises also various connectors or fasteners.

[0103] Once above the target delivery container, the at least one door leaf 70 rotates relative to the opposing sidewalls to the open position to dispense one or more items 64 from the dispenser container. To move the at least one door between the closed and open positions, the at least one door leaf is rotatably mounted to the body 59 of the dispenser container by a hinge mechanism 72 such that the at least one door leaf 70 is rotatable relative to the at least one of the opposing sidewalls. In the example shown in Figures 7 and 8, the at least one door leaf is rotatably mounted to at least one of the opposing sidewalls of the dispenser by the hinge mechanism 72. The hinge mechanism 72 shown in Figure 10 comprises a first set of hinge members 74 and a second set of hinge members 76, the first set of hinge members 74 interdigitate the second set of hinge members 76 when the at least one door leaf is offered up to the sidewall of the dispenser container. The first and second sets of hinge members 74, 76 are connected together by a hinge pin 78 that defines the rotational axis of the door leaf. A drive mechanism 80, e.g., an electric motor is coupled to the hinge mechanism to rotate the at least one door leaf 70 about the hinge axis, X-X, between the open and closed positions.

[0104] The drive mechanism 80 can be actuated to rotate the door leaf 70 between the closed and open positions by any suitable actuator known in the art. These include but is not limited to electrical means, e.g., switch, or electromechanical means, e.g., solenoid. The actuator 82 can be configured to receive one or more signals wirelessly or over a wired network to actuate the drive mechanism 80 to move the at least one door leaf 70 between the closed and open positions. The one or more signals can be sent by a local controller 84 in the load handling device 30 or by a central or master controller (not shown) external of the load handling device over a communication network. The communication network, for example, can be a local area network (LAN), a wide area network (WAN) or any other type of network. A dispenser controller (One or more processors of the controller can execute instructions stored in a ROM and / or RAM to actuate the drive mechanism. The communication signal to actuate the at least one door leaf to move between the closed and open positions can be via either far field or near field wireless communication protocol such as at least one of Bluetooth, Zigbee and / or the like or Wi-Fi emitters. The dispenser container may, optionally, comprise a communication module

[0105] 86 that couples with the robotic load handling device, more specifically, the local controller of the robotic load handling device when the dispenser container is received in the container receiving space of the robotic load handling device. Figure 9 is an example of a block diagram 81 showing the relationship between the communication module 86, the dispenser controller

[0106] 87 and the actuator 82 to actuate at least one door leaf to move between closed and open position in the dispenser container 58, and its interaction between the local controller 84 of the load handling device via a communication module 86b. The communication modules 86, 86b may comprise a wireless receiver that is configured to receive wireless signals from the local controller 84 of the robotic load handling device via a transmitter or an external controller (not shown). Alternatively, the communication modules 86, 86b may comprise one or more electrical contacts that physically contact with a correspondingly number of electrical contacts in the robotic load handling device. For example, the lifting frame of the grabber device may comprise one or more electrical contacts which physically contact the one or more electrical contacts on the dispenser container to communicate with the actuator 82 to the drive mechanism 80 (see Figures 25 and 26). Alternatively, the controller for actuating the drive mechanism can be integrated into the dispenser container and configured to either receive signals to actuator the drive mechanism via the local controller in the robotic load handling device or from the master controller external of the robotic load handling device. It will further be appreciated that the instructions may be communicated to the dispenser controller or control system in numerous ways. For example, the instruction may be “Go to position x there and dispense on arrival”, or the instruction may be issued in two sections, rather first “go to position x” and then “dispense”. Further details of the transmittal of instructions to dispenser controller to operate the dispenser container is discussed further below.

[0107] Power to operate the drive mechanism, actuator and / or the dispenser controller 87 can be drawn from a power source integrated or incorporated into the body of the dispenser container 58, e.g., integrated into the hinge mechanism, or from an external power source, e.g., from the power source of the robotic load handling device. For example, electrical contacts are established when the grabber device engages with the dispenser container to draw power from the robotic load handling device. In the particular example of the present disclosure, a battery is incorporated into a comer of the body of the dispenser container. In both cases, the power source could be any rechargeable power source known in the art including but is not limited to a rechargeable battery, capacitor, supercapacitor etc. An inventory item dispensed from the dispenser container is intended to free fall under gravity when the door leaf is moved to the open position. However, the speed by which the item can be dispensed from the dispenser container can be controlled by controlling the angular orientation of the door leaf. When the door leaf is orientated substantially vertically, the opening in the bottom wall of the dispenser wall is at its maximum size and there is little resistance to prevent the item from free falling under gravity. Such an open position can be termed a fully open position. When the door leaf is substantially horizontal or at a very shallow angle, the opening in the bottom wall of the dispenser container is closed or partially open and the item experiences maximum resistance to fall from the dispenser container. Such a closed position can be termed a fully closed position. Between these two extremes, the angular orientation of the at least one door leaf can be varied. For example, rotating the door leaf such that the door leaf is at an acute angle to the horizontal has a tendency to cause one or more items to be dispensed from the dispenser container slower than when the door leaf is at an obtuse angle due to the resistance experienced by the item when falling from the dispenser container.

[0108] In addition to, or as a result of the angle of orientation of the door leaf, the frictional contact between the item and the surface characteristics of the door leaf also has an influence on the speed by which the item can be dispensed from the dispenser container. A contact surface having a relatively large frictional surface between the item and the surface of the door leaf results in a slower descent from the dispenser container as the downward force as a result of gravity is resisted by the relatively high frictional contact between the item and the surface of the door leaf. Similarly, a small frictional contact between the item and the surface of the door leaf results in a faster descent of the item from the dispenser container. The surface characteristics of the door leaf can be tailored to modify the frictional contact between the item and the surface of the door leaf. For example, the surface of the door leaf can be treated with a coating that alters the sliding characteristics of an item on the door leaf. Examples of modifying the surface characteristics of the door leaf to alter its coefficient of friction include but is not limited to the use of an abrasive material or a rubberised material to provide a high frictional surface to the use of various slip materials, e.g., PTFE, to reduce the frictional contact. As a result, the speed by which an item can be dispensed from the dispenser container can be tailored by controlling the angular orientation of the door leaf and / or the surface characteristics of the door leaf. The angular orientation of the door leaf and the surface characteristics of the door leaf are generally mutually inclusive in the sense that one influences the other.

[0109] In the present invention, a gear mechanism 88 can be coupled to the drive mechanism 80 to control the angular orientation of the at least one door leaf 70 between the closed and open positions. Not only would a gear mechanism 88 control the angular orientation of the at least one door leaf, the drive mechanism 80 coupled to the gear mechanism 88 can control the speed or angular speed by which the at least one door rotates between the closed ad open positions. The speed by which an inventory item can, thus, be dispensed from the dispenser container can also be controlled by controlling the angular speed of the at least one door leaf. In the particular example of the present invention shown in Figures 1 l(ato d), the gear mechanism 88 comprises a worm drive mechanism comprising a worm gear 90a and worm wheel 90b. The worm wheel 90b can be integrated into the hinge mechanism and the worm gear 90a is coupled to the drive mechanism 80 such that rotation of the worm gear 90a by the drive mechanism drives rotation of the worm wheel 90b to rotate the door leaf between the open and closed positions. The worm wheel 90b is shown integrated into the first set of hinge members 74 of the hinge mechanism 72 and the worm gear 90a extends downwardly from the second set of hinge members 76 such that the worm wheel 90b meshes with the worm gear 90a when the door leaf 70 is offered up to the sidewall of the dispenser bin. The drive mechanism can be integrated into the sidewall of the dispenser bin and is configured to drive rotation of the worm gear to open and close the door leaf. Examples of a drive mechanism to drive rotation of the worm gear include but is not limited to an electric motor.

[0110] The advantage of the worm gear mechanism over other gear mechanisms to control the rotation of the door leaf between the closed and open position is not only that its drive axes are 90° to each other so as to conceal the gear mechanism within the sidewalls and bottom wall of the dispenser container, the worm gear mechanism has a high gear ratio making it easier to move relatively heavy loads or overcome resistance when loads are resting on the door leaf. In addition, the worm gear mechanism provides the ability to self-lock the door leaf at different angles or orientations between the closed and open positions. This provides the ability for an item resting on the door leaf to be released from the dispenser bin more slowly preventing the item to freefall under gravity. Controlling the rate by which the item slides along the surface of the door leaf as it is dispensed from the dispenser container has advantages to control the release of fragile items, e.g., eggs or glass. Orientating the door leaf at a shallow angle relative to the horizontal slows the descent of the item from the dispenser container and thereby, controls the speed by which the item can be lowered into the delivery container. Equally, controlling the angle of orientation of the door leaf when dispensing an item can also control the placement of the item dispensed into the delivery container.

[0111] A sensor system can be used to measure the angular orientation of the door leaf 70 between the closed and open positions (see Figure 11 (e and f). One or more signals from the sensor system is used by the dispenser controller 87 to control the rotation of the door leaf 70 between the closed and open position. In the particular example of the present disclosure, the sensor system comprises a position sensor 91a, 91b for determining the position of the door leaf 70 at the closed and / or open positions, and a rotary encoder (not shown) for measuring the number of rotations of the gear mechanism relative to the closed and / or open positions. The position sensor 91a, 91b provides a reference point from which the rotary encoder measures the number of rotations of the gear mechanism. The number of rotations of the gear mechanism provides an indication of the angular orientation of the door leaf relative to the closed or open positions measured from the position sensor. In the particular example shown in Figures 1 l(e and 1), the position sensor comprises a first position sensor 91a indicative when the door leaf is in the closed position (Figure 11(e)) and a second position sensor 91b indicative when the door leaf is in the open position (Figure 11(f)). An example of a type of position sensor is a Hall effect sensor. As shown in Figure 11(e) and 11(f), a magnet 95 is integrated into one or more hinge members of the hinge mechanism, in particular one or more hinger members of the first set of hinge members. A Hall sensor is positioned adjacent the hinge member such that when the magnet is adjacent the Hall sensor a signal is generated which is communicated to the dispenser controller. As shown in Figure l l(e and f), a first magnet is integrated into the hinge member and positioned such that the first magnet interacts with the first position sensor 91a when the door leaf is in the closed position (see Figure He). Likewise, a second magnet 95 is integrated into the hinge member and positioned in the hinge member such that the second magnet interacts with the second position sensor 91b when the door leaf is in the open position (see Figure 1 If). The rotary encoder measures the rotation of the gear mechanism between the closed and open positions of the door leaf. One or more signals from the rotary encoder is used by the dispenser controller 87 to determine and control the angular orientation of the door leaf relative to the closed and / or open positions. As discussed above, one or more signals from the sensor system can be used by the dispenser controller to control the release of one or more items from the dispenser container.

[0112] In the case where one or more shopping bags or other carrier bags are placed in the delivery container, it is important that the items to be dispensed in the delivery container is placed in the correct shopping bag. Multiple shopping bags 92 can be placed in the delivery container 90 to separate different item types in the delivery container based on the type of item, e.g., tinned items and fragile items as shown in Figures 12(a and b). Not only separating certain item types in the different shopping bags in the delivery container mitigate the risk of damage to one or more fragile items but separating the items in the delivery container may also prevent cross contamination or it is simply adhering to a particular customer’ s taste. In any case, it is desirable for the dispenser container 58 to not only carefully place the items in the delivery container but to also place the item in the correct position or shopping bag in the delivery container. In the example shown in Figure 13(a and b), the at least portion of the bottom wall 62 of the dispenser container 58 comprises a plurality of door leaves 70 that cooperate with each other to carefully dispense one or more items from the bottom of the dispenser container. In the particular example shown in Figures 13(a and b), the plurality of doors leaves 70 comprises a first and a second sets of opposing door leaves that cooperate to control the size of the opening in the bottom 62 of the dispenser container 58. The size of the inventory item to be dispensed from the dispenser container can, of course, depend on the size of the opening in the bottom wall of the dispenser container. In the example shown in Figure 8, the bottom wall of the dispenser container 58 comprises a first and second openings and plurality of door leaves comprises two opposing door leaves 70 that are each rotatable to close the first and second openings respectively. However, the example shown in Figures 13(a and b), the plurality of door leaves comprises two sets of door leaves 70, each of the two sets of door leaves comprises three door leaves that are each rotatable relative to the opposing sidewalls to close their respective openings. For avoidance of doubt, each of the plurality of door leaves can be construed to function as a trap door in the sense that the bottom wall of the dispenser mechanism (e.g., dispenser container) comprises a plurality of trap doors and each of the plurality of the plurality of trap doors being moveable between the closed and open positions relative to the opposing sidewalls.

[0113] Each of the plurality of the door leaves can be rotatably mounted to the body 59 of the dispenser container by the hinge mechanism 72. The sensor system discussed above can used to control the angular orientation of each of the plurality of door leaves. In the example shown in Figures 13(a and b), each of the plurality of the door leaves is rotatably mounted to the opposing sidewalls of the dispenser container. Movement of each of the plurality of door leaves 70 between the closed and open positions relative to the opposing sidewalls 60 can be in synchronisation or independently relative to each other. The gear mechanism 88 coupled to the drive mechanism 80 discussed above can control the angular orientation of each of the plurality of door leaves and thereby, control the size of the opening in the bottom wall of the dispenser container. It will be appreciated that the number of door leaves forming at least a portion of the bottom wall of the dispenser container depends on the number of placement requirements in the delivery container and / or the size of the inventory items to be dispensed. For example, the plurality of door leaves can function as individual “fingers” to control the size of the opening in the bottom wall of the dispenser container and thereby, control the placement of one or more inventory items into a delivery container below. The number of door leaves actuated to move between the closed and open position relative to the opposing sidewalls can be selected to vary the opening in the bottom wall of the dispenser container. It will be appreciated that other means to drive and control the movement of each of the plurality of door leaves between the closed and the open position is applicable in the present disclosure.

[0114] The hinge mechanism 72 can be configured such that a plurality of door leaves can be driven to rotate between the closed and open position relative to the opposing sidewalls of the dispenser container by a single drive mechanism, i.e., the plurality of door leaves is coupled to a single drive mechanism. For example, the single drive mechanism can be coupled to the hinge pin 78 to drive rotation of the plurality of door leaves rotatably mounted to one of the opposing sidewalls of the dispenser container between the closed and open position relative to the opposing sidewalls in synchronisation. Alternatively, each of the door leaves can be driven between the closed and open position by its own dedicated drive mechanism. This allows each of the plurality of door leaves to move independently relative to each other between the closed and open position. To facilitate accurate placement of one or more items into the correct position within a delivery container, the dispenser container may optionally include a vision system, such as a camera or an array of cameras. The operation of the trap door may be controlled in response to signals generated by the vision system. The vision system can be configured to detect conditions in which one or more items obstruct or foul the trap door, or otherwise prevent their release from the dispenser container.

[0115] Upon detecting such a condition, the dispenser controller may initiate corrective action to clear the obstruction. For example, the controller may actuate the drive mechanism to repeatedly move the trap door between its open and closed positions in order to dislodge the fouling item or items and restore normal operation. The rechargeable power source of the load handling device, as described in the introductory section of this specification, may be utilised to charge the rechargeable power source of the dispenser container 58 through engagement with the grabber device 139 (see Figures 25 and 26). A portion of the electrical power from the load handling device’s rechargeable power source can be transferred to the dispenser container’s rechargeable power source via one or more of the tethers 38 suspending the grabber device 139 from the load handling device. Alternatively, power transfer may occur through a dedicated electrical cable (not shown_ separate from the lifting tethers 139. Employing at least two of the lifting tethers as conductors for current transfer reduces the need for a separate cable. However, the present invention is not limited to power transfer via the lifting tethers, and the use of separate electrical cables for transferring power likewise falls within its scope.

[0116] In the embodiment illustrated in Figures 25 and 26, the dispenser container 58 comprises a charge receiving interface 186 configured to engage with a charge providing interface 186b of the grabber device 139 when the grabber device connects to the dispenser container 58. In this embodiment, the charge providing and charge receiving interfaces 186b, 186 respectively comprise multiple contact pads — charge providing pads and charge receiving pads — that physically engage to facilitate power transfer. To enable reliable electrical connection, the charge receiving interface is preferably positioned on the rim of the dispenser container 58. A subset of the contact pads (for example, two) is employed to transfer power to the dispenser container’s rechargeable power source, while the remaining pads (for example, another two) may be used for communication with the local controller of the load handling device to operate the hinge mechanism discussed above. The local controller can regulate the current supplied via the charge providing pads in accordance with the condition of the rechargeable power source of the load handling device and / or the dispenser container, which may be determined based on one or more parameters such as voltage, temperature, state of charge, depth of discharge, or charging status.

[0117] As the grabber device 139 approaches and engages the dispenser container, charge receiving pads 186b mounted on the grabber device are brought into electrical contact with corresponding charge providing pads 186 on the dispenser container 58. In the embodiment shown in Figures 25 and 26, one or more recesses or holes 11 formed in the rim of the dispenser container engage with gripper elements 188 provided on the underside of the grabber device 139. The charge contacts are drawn together with sufficient pressure to minimise electrical contact resistance between the mating surfaces. Either or both of the contact pads may be resiliently biased in a vertical direction to enhance the contact force between the interfaces. In addition, locating pins 190 mounted to the grabber device assist in aligning the charge providing pads of the grabber device with the corresponding charge receiving pads of the dispenser container to ensure proper engagement.

[0118] In addition to, or as an alternative to, transferring power through physical contact between the interfaces, power may also be transferred wirelessly. In such embodiments, the charge providing interface comprises a wireless charging transmitter coil, and the charge receiving interface comprises a corresponding wireless charging receiver coil. When the grabber device engages with the dispenser container, the transmitter and receiver coils are positioned in close proximity to enable inductive coupling. As is known in the art, an alternating current (AC) flowing through the transmitter coil generates a time-varying magnetic field, which induces a current in the receiver coil in accordance with Faraday’s law of induction. This induced current is then used to charge the dispenser container’s rechargeable power source. A first AC / DC converter in the load handling device converts direct current (DC) from its rechargeable power source into AC to drive the transmitter coil, while a second AC / DC converter in the dispenser container converts the induced AC back into DC for charging its rechargeable power source. Wireless charging provides several advantages, including the elimination of physical contact between conductive interfaces, which enhances operational safety and reduces wear and tear of the contact surfaces. Consequently, maintenance and replacement of worn contact pads are reduced or avoided. In cases where the rechargeable power source of the dispenser container is a capacitor, such as a supercapacitor, sufficient charge can be transferred wirelessly to operate the drive mechanism of the hinge assembly.

[0119] In addition to transferring power, the interface between the grabber device and the dispenser container may also facilitate communication of control instructions. These instructions govern the movement of the hinge mechanism between its open and closed positions. Figure 27 illustrates the interaction between the load handling device 30 (referred to as the “hot”) and the dispenser container 58. In the example depicted, power is transferred wirelessly from the load handling device 30 to the rechargeable power source 194 of the dispenser container, while control instructions for the hinge mechanism are transmitted from the load handling device to the dispenser container’s controller 87.

[0120] Typically, one or more load handling devices operating on track system receive operational instructions from a master controller via the base station 192, which directs them to retrieve specific storage containers from designated storage locations within the grid. A wireless communication network, possibly involving one or more base stations, provides the communication infrastructure between the master controller and the load handling devices. Upon receiving instructions, the controller 84 within the load handling device governs the various drive mechanisms to control movement along the track system. For example, the load handling device may be instructed to retrieve a storage container from a specified storage column. These instructions may include a series of movements in the X-Y plane of the tracks. Once positioned, the lifting mechanism is actuated to engage the container and lift it into the receiving space within the load handling device for transport to another location on the grid, such as a drop-off port.

[0121] In addition to these retrieval operations, the master controller may instruct the load handling device to control the operation of the hinge mechanism of a dispenser container. Communication between the load handling device and the dispenser container may occur either wirelessly or via physical contact through a communication interface. Upon receiving such instructions, the controller 87 of the dispenser container actuates movement of the door leaf between its open and closed positions to dispense one or more items into a delivery container, as described previously.

[0122] In some embodiments, rather than charging the dispenser container’s rechargeable power source 194, power from the load handling device may be supplied directly to operate the hinge mechanism and associated controller 87 via contact with the grabber device. The rechargeable power source 194 of the dispenser container can thus act as a backup power supply, ensuring continued operation in the event of insufficient or interrupted power from the load handling device when the grabber device disengages. In the particular example of the present disclosure, the rechargeable power source comprises a capacitor, e.g., supercapacitor. Capacitors are advantageous over other type of rechargeable energy storage means such as batteries in that they can be rapidly charged in the order of seconds and have a longer life time than conventional batteries, and thus, have the ability to store large amounts of power over a relatively short period of time. This allows fast recharging of the capacitor modules, reducing any recovery time due to charging. Other advantageous include an increased life cycle length compared to batteries. Batteries are only able to manage a certain number of charging and discharging cycles and capacitors can manage significantly more. Moreover, the use of capacitors in this context enables the rechargeable power source to self-discharge.

[0123] The drive mechanism 196, controller 87, and / or sensor system (not shown) together constitute an electrical load within the dispenser container 58. As the magnitude of the electrical load increases, so too does the power required to supply it. To prevent the rechargeable power source of the dispenser container from contributing excessively to the overall weight of the dispenser container, it is preferable that the rechargeable power source be lightweight. However, a lightweight power source inherently limits the amount of charge it can store — i.e., its charge capacity. This reduced capacity constrains the selection of electrical components that can be employed to operate the dispenser mechanism, such as the drive mechanism 196 and controller 87.

[0124] High energy-consuming components can rapidly deplete the stored power within the dispenser container’s rechargeable power source and / or that of the robotic load handling device. One example of such a high-demand component is the dispenser controller 87, which, in some systems, must process complex control signals originating from the master controller that relate to the operation of the robotic load handling device on the track system. In the present invention, control instructions for actuating the one or more trap doors between their closed and open positions are instead received and processed by the local controller 84 of the robotic load handling device. This arrangement enables the dispenser container to utilize a simpler, low-power controller — such as a microcontroller 87 — without sacrificing functionality. The instructions transmitted from the robotic load handling device are converted into a simplified format that can be readily interpreted by the dispenser controller 87, thereby minimizing processing requirements and overall power consumption. In operation and depending on whether the dispenser container is dispensing one or multiple items, the drive mechanism 80 can be instructed to move at least one of the door leaves to the open position in response to one or more signals from the controller such that the opening in the bottom wall of the dispenser container is sized to release one or multiple items from the dispenser container. For less fragile items, e.g., salad, the drive mechanism coupled to the gear mechanism can be instructed to move the at least one of the door leaves to the fully open position to maximise the size of the opening and allow the inventory item to free fall under gravity. For fragile items or an inventory item of a relatively large size, the size of the opening in the bottom wall of the dispenser container can be controlled by controlling the angular orientation of one or more of the plurality of door leaves.

[0125] For proper product placement in the delivery container, the one or more of the plurality of door leaves can be chosen to open a select portion of the bottom wall of the dispenser container such that an inventory item supported by the one or more of the plurality of door leaves falls into the correct portion of the delivery container or shopping bag. Different portions of the bottom wall of the dispenser container can be opened to selectively dispense one or more of the inventory items from the dispenser container into the delivery container. The advantage to having a plurality of door leaves for selectively opening different portions of the bottom wall of the dispenser container is the ability to dispense a plurality of inventory items into a batch of the plurality of delivery containers when fulfilling a batch of customer orders in a single operation of the robotic load handling device on the track system.

[0126] In the situation where the deliver container contains one or more shopping bags, it is important that the dispenser container deposits the correct items into the shopping bag and where there are multiple shopping bags in the delivery container into the correct shopping bag. Typically, a shopping bag is constructed from thin, flexible, plastic film material that is sealed at one end and having an opening 100 at the other end for receiving one or more items to be carried. However, due to the flexible nature of the shopping bag 92, the opening 100 of the shopping bag 92 has a tendency to collapse in the delivery container 90 and may prevent one or more items to be received in the opening 100 of the shopping bag 92. To ensure that an item is deposited in the shopping bag, the door leaf 70 may comprise one or more outwardly diverging profiles 98 to define a bag opening geometry that interacts with the shopping bag, more specifically the opening of the shopping bag, to prise the shopping bag open when the door leaf 70 is moved to the open position relative to the sidewall of the dispenser container. In the particular example shown in Figures 14 and 15, the at least one door leaf 70 has an underside comprising at least one profile 98 comprising a continuous step or ridge that tapers or diverges outwardly from a narrow portion to a wide portion. The at least one profile 98 on the underside of the at least one door leaf interacts with the opening of the shopping bag to cause the opening of the shopping to be prised open when the at least one door leaf is moved to the open position due to the outwardly diverging nature of the at least one profile (see Figure 15). During operation when depositing one or more inventory items into a shopping bag, the narrow portion of the at least one profile initially interacts with the mouth 100 of the shopping bag 92 and gradually expands as the at least one profile 98 diverges outwardly when the at least one door leaf is rotated towards the open position relative to the sidewall of the dispenser container, i.e., the angle of orientation of the door leaf to the horizontal increases as it approaches towards the vertical. The at least one profile shown in Figure 14 is shaped with a “Y” profile. However, it will be appreciated that the geometric shape of the at least one profile can be different to prise open the mouth of the shopping bag when rotating towards the open position. In all cases, the at least one profile form outwardly diverging steps for interacting with the mouth of the shopping bag.

[0127] Instead of the need for a robotic load handling device operative on the track system to carry the dispenser container to dispense one or more inventory items into the batch of the plurality of delivery containers in storage in the grid framework structure, the trap door comprising the at least one door leaf can be integrated into a body 104 of the robotic load handling device to define a robotic dispenser device 102 as shown in Figure 16. The body 104 of the robotic dispenser device 102 is shown in Figure 16 comprises opposing sidewalls 160 and a bottom wall 162. The functionality of the robotic dispenser device 102 to move on the track system can be the same as described for the robotic load handling device discussed above, i.e., the robotic dispenser device comprises a directional change mechanism comprising a wheel assembly 134, 136 to move in orthogonal X and Y directions on the track system. The wheel assembly is mounted to the opposing sidewalls of the body 104 of the robotic dispenser device 102.

[0128] Like the dispenser container, one or more items 64 can be dispensed from the body 104 of the robotic dispenser device 102 by incorporating the trap door comprising the at least one door leaf 162 to the body of the robotic dispenser device 102. Like the dispenser container, the at least one door leaf is rotatably mounted to the body of the robotic dispenser device by the hinge mechanism (to at least one sidewall of the body of the robotic dispenser device) and driven to move between the closed and open positions relative to the at least one sidewall 160 by the drive mechanism discussed above. The drive mechanism can be coupled to a gear mechanism to control the rotation of the at least door between the closed and open position relative to the opposing sidewalls 160, and allow the at least one door leaf to self-lock at different angular orientations. For the robotic dispenser device to dispense one or more items into the batch of the plurality of delivery containers below, the at least one door leaf can comprise a plurality of door leaves that can operate independently relative to each other by the drive mechanism to open at least one portion of the bottom wall of the body of the robotic dispenser device for an item to be released from the body of the robotic dispenser device. In the particular example shown in Figure 16, the at least one door leaf comprises two opposing door leaves, each of the two opposing door leaves being arranged to close an opening in at least a portion of the bottom wall of the body of the robotic dispenser device. It will be appreciated that the trap door can comprise any number of door leaves as shown in Figures 13(a and b), each of the door leaves being configured to close different openings in the bottom wall of the body of the robotic dispenser device to control the size of the opening in the bottom wall to dispense at least one inventory item or different size inventory items.

[0129] The pick station 106 comprising the picking mechanism to load or stock the dispensing mechanism with the inventory items to be dispensed can be carried out in-situ on the grid framework structure or outside of the grid framework structure. Transferring one or more inventory items from a storage container into a delivery container in-situ on the grid framework structure removes the need to transport the dispenser mechanism to a location outside of the grid framework structure. This not only increases the operational efficiency of the storage and retrieval system when fulfilling multiple customer orders but also alleviates congestion of robotic load handling devices at the port waiting to deliver a storage container to the inventory handling station. For example, batch picking where multiple orders are picked at once reduces the number of back-and-forth trips between the inventory handling station and the grid framework structure.

[0130] In a first example of the present disclosure, the picking mechanism 108 may comprise a robotic arm 110 mounted to the track system 15 of the grid framework structure 14, more specifically to a grid cell of the track system (herein referred to as on-grid robotic pick (OGRP)). The robotic arm 110 can be mounted to the track system such that the robotic arm is received within asingle grid cell 138 ofthe track system (see Figure 21). Figures 17 show a schematic depiction of a robotic picking mechanism, which comprises a plinth upon 112 which a robotic arm 110 is received. The plinth 112 is of a size and shape such that it may be received within the aperture of a grid cell formed by intersecting horizontal grid members. The plinth may be substantially rectangular in shape. The plinth is connected to the framework of the storage system such that the robotic arm is mounted on the storage system. For example, the plinth may be connected to one or more of the upright members of the storage system. Alternatively, the plinth may be connected to one or more of the horizontal members of the storage system. The plinth may be connected to one or more of the upright members and one or more of the horizontal members of the storage system. The surface of the plinth may extend across substantially the entirety of the aperture of the grid cell in which it is received. This will reduce the risk that a dropped product may fall into the storage system, potentially interfering with the operation of the storage system. Alternatively, the surface of the plinth may only partially extend across the area of the grid cell in which it is received.

[0131] In an alternative, a mount may be used to connect the robotic arm to the framework of the grid framework structure. One or more mount members may mount the robotic arm, for example the base of the robotic arm, to one or more members of the storage system. The robotic arm may be mounted to: one or more upright members of the storage system; one or more horizontal members of the storage system; or one or more upright and one or more horizontal members of the storage system. The mount may be configurable such that the picking mechanism may be retracted below the level of the track system.

[0132] The robotic arm comprises a base 114, first joint 116, upper arm portion 122, second joint 120, lower arm portion 118, thirdjoint 124 and end effector 126. The base 114 extends substantially vertically from the plinth 112 and is connected to the lower arm portion 118 by the first joint 116, or shoulder. The upper arm portion 122 is connected to the lower arm portion 118 by the second joint 120, or elbow. The lower arm portion 118 is connected to the end effector 126 by the third joint 124, or wrist. The first joint, the second joint and the third joint may be selectively actuated such that the end effector may be moved along one or more of the x-axis, the y-axis and the z-axis (see Figure 17). This means that the end effector may be moved into a first container such that it can be activated to engage with a product stored within that container. The product may then be lifted from the first container and the end effector may then be moved to a second container. Typically, in the art when fulfilling one or more customer orders into one or more delivery containers, the first container is the storage container containing one or more items of a particular SKU type to fulfil the one or more customer orders and the second container can be a delivery container used to dispatch the fulfilled customer orders to the customer’s destination. The delivery container can be purposively designed to be picked up by a robotic load handling device operative on the track system or a combination of the storage container and the delivery container. In the particular example discussed in the introduction, the delivery container is nested in the storage container to form a storage combination such that the delivery container can be picked up by the robotic load handling device.

[0133] Typically, the plurality of tracks are arranged such that eight grid cells 128 surround the single grid cell 130 supporting the mount for the robotic arm 110. This can be demonstrated by the illustration of the picking mechanism 108 on the track system shown in Figure 21. Generally, eight grid cells (shaped area) are reserved for use by the robotic arm and can be divided into a first zone 130 and a second zone 132. However, it will be appreciated that the number of grid cells that are reserved for the robotic arm can vary depending on the size of each of the grid cells and the position of the robotic arm on the grid framework structure. Each of the first and second zones 130, 132 comprises one or more grid cells for receiving a delivery container (or storage combination) and one or more gid cells for receiving a storage container. Typically, the first zone shown in Figure 21 can be reserved for receiving one or more delivery containers (or storage combination) and the second zone can be reserved for receiving one or more storage containers containing items of a particular SKU type to fulfil the one or more customer orders in the one or more delivery containers in the first zone. The one or more grid cells of the first zone and the second zone are in close proximity or adjacent to the robotic arm in the sense that the storage containers and delivery containers in the first and second zones are accessible by the robotic arm. The number of customer orders that can be fulfilled in-situ on the grid framework structure by a given robotic arm mounted to the track system is, thus, limited by the span of the robotic arm which is typically, a single grid cell. The span of the robotic arm can be demonstrated by the shaded grid cells 128 in Figure 21. As a consequence, there is a tendency for the eight grid cells surrounding the robot arm to be fully occupied with delivery containers and storage containers when fulfilling customers reducing the capacity of the picking mechanism to fulfil additional customer orders. Typically, to increase the pick rate of customer orders and thus, the operational efficiency of the storage and retrieval system when fulfilling customer orders is to increase the number of robotic arms operational on the track system. This not only increases the cost to fulfil customer orders due to the increased capital costs of the number of robotic arms to fulfil multiple customer orders but also reduces the storage capacity of the grid framework structure since the mounting for the robotic arm occupies valuable storage space in the grid framework structure.

[0134] However, if some of the customer orders could benefit from batch picking, this not only reduces the frequency of the trips to the pick station 106 but also alleviates the congestion at the pick station 106 freeing up grid cells at the pick station for more orders to be fulfilled and ultimately, a reduction in the number of robotic arms to fulfil the same number of customer orders. Instead of fulfilling customer orders at the pick station, in the present disclosure, the customer orders that are collated into a batch of customer of orders on the basis that they have at least one item having at least one attribute that is in common by the warehouse management system discussed above (herein referred to as batch picking). As a result, the customer orders can be fulfilled whilst their corresponding delivery containers are still in their current storage location in the grid framework structure regardless if they are not accessible by the robotic arm. In other words, the robotic arm can be used to batch pick a plurality of customer orders into the batch of the plurality of delivery containers without the need to transport the delivery containers to the pick station to receive the inventory items. However, it will be appreciated that the number of pick stations on the grid framework structure is not limited to one and can be a plurality of plurality of pick stations to further increase the operational efficiency of the storage and retrieval system.

[0135] To fulfil a batch of customer orders and thus, benefit from batch picking, in the present disclosure, one or more grid cells of the first zone are reserved for the receiving the dispenser mechanism discussed above. This could be either the dispenser container or the robotic dispensing device discussed above. The picking mechanism can thus be instructed to transfer one or more inventory items from the storage container in the second zone to the dispensing mechanism in the first zone of the track system. To batch pick into the batch of the plurality of delivery containers, a single storage container containing inventory items having a common attribute for the purpose of batch picking is delivered to the second zone and the dispensing mechanism is delivered to the first zone. In the illustration shown in Figure 21, the dispensing mechanism occupies a single grid cell in the first zone and the single storage container occupies a single grid cell in the second zone. In the case where the dispenser mechanism is the dispenser container, the phrase “occupying a single grid cell” is construed to mean that the dispenser container is deposited into a storage column arranged below a first grid cell 140 of the first zone 130. Likewise, the storage container is deposited into a storage column that is arranged below a second grid cell 142 of the second zone 132.

[0136] Once the item is appropriately placed within the dispensing mechanism then the end effector 126 may be deactivated such that the product is deposited into the dispensing mechanism. The process of batch picking can be explained by the processing steps illustrated in the flowchart shown in Figure 6 and the additional processing steps shown in Figure 22. The processing steps between the steps A (step 44) and B (step 46) in the flowchart shown in Figure 6 to transfer the inventory items for batch picking is illustrated in Figure 22. In operation and following collating a plurality of customer orders into a batch of customer orders on the basis that they each have at least one item having an item in common in their order in step 44, the warehouse management system identifies the delivery containers in storage in the grid framework structure to fulfil a batch of customer orders. This may involve locating the storage locations of the delivery containers and if necessary, dig and reposition the delivery container so that the delivery container is able to capture one or more inventory items dropped from a grid cell opening above, i.e., the mouth of the delivery container is exposed below a grid cell opening. To load the dispensing mechanism with one or more of the common items for batch picking, the warehouse management system identifies and locates the storage container in storage in the grid framework structure containing the plurality of the inventory items 146 and instructs a robotic load handling device operative on the track system to transport the storage container to the second zone of the track system that is accessible by the robotic picking mechanism 148; more specifically the end effector 126 of the robotic arm 110. The end effector 126 may comprise a suction device, a pair of opposed grippers, a plurality of fingers or other known effectors which can be used to grip and lift products. It should be understood that the specific configuration of the robotic arm shown in Figure 17 is purely exemplary and that robotic arms of other configurations could be used. For example, the robotic arm may comprise a greater or lesser number of portions and joints. The picking mechanism may further may comprise an optical sensor, which may be located on the upper surface of the plinth. The optical sensor may be used in the identification of products in the picking process. The picking mechanism may comprise a plurality of optical sensors. In one example, the picking mechanism may comprise four optical scanners, with one optical scanner being located at, or near to, each comer of the plinth. The or each optical scanner may comprise a barcode reader. In an alternative arrangement, one or more barcode scanners may be installed on the robotic arm, such that the barcode scanner(s) move with the arm. In a specific implementation, two barcode scanners may be installed onto the arm.

[0137] The picking mechanism may further comprise a camera array (not shown), which is located above the plinth and arranged so as to be able to view the area in which the end effector will operate. The camera array may have a rectangular form but it should be understood that the camera array may take other forms, for example, square, elliptical circle, cruciform etc., or may comprise a plurality of discrete cameras. The camera array may further comprise lighting elements to illuminate the area in which the end effector will operate. The camera array may comprise one or more 3D cameras. The camera array may be suspended from the ceiling of the building which houses the storage system.

[0138] The picking mechanism may further comprise one or more cameras mounted on the robotic arm. A camera may be mounted on, or near to, the end effector. A camera may be mounted on or near the wrist. In addition, or alternatively, a camera may be mounted on or near to the elbow of the robotic arm. The use of a camera, or cameras, mounted on the robotic arm may be in addition to the camera array or as an alternative. The or each camera may be provided with lighting elements to illuminate the interior of a container when an item is being picked or deposited. One or more cameras may be located elsewhere on the picking mechanism. For example, a camera may be used as a barcode scanner. If barcode scanner(s) are fitted to the arm then the lighting element of the barcode scanner(s) may be used to illuminate the interior of a container.

[0139] The picking mechanism may be controlled by the warehouse management system discussed above and comprises a computer device, which may be used to control the movement of the robotic arm and the activation of the end effector. Images from the camera array may be fed to the computer device for processing to assist in the identification and / or grasping of items stored in containers. The computer device may be located beneath the plinth of the picking mechanism. The picking mechanism may, in an alternative, be connected to a remote computer device, for example by a wired Ethernet connection (or other network connection). Such a remote computer device may be used to control a plurality of picking mechanisms. The remote computer device may form part of the warehouse management system comprising a central computer used to control the robotic load handling devices. In a further alternative, a cloud computing platform may be used to control the picking mechanisms within the storage system. A computer device may be located at or near to the camera array such that images captured by the camera array can be processed and then transmitted to an associated picking mechanism. A computer device located at or near to the camera array may perform a degree of image preprocessing with further image processing being performed at the picking mechanism

[0140] To transfer one or more of the inventory items to the dispenser mechanism, the warehouse management system instructs the dispenser mechanism to be transported to the first zone of the track system adjacent the picking mechanism 144. In the case where the dispenser mechanism is a dispenser container discussed above, the warehouse management system instructs a robotic load handling device operative on the track system to pick up the dispenser container via its engagement features and deposit the dispenser container to a grid cell in the first zone. For the purpose of explanation, the dispenser container is deposited in a first grid cell of the first zone and the storage container is deposited in a second grid cell of the second zone. The first and second grid cells are adjacent the picking mechanism such that they are accessible by the robotic arm. The robotic arm can be instructed to transfer one or more of the items from the storage container in the second grid cell to the dispenser container in the first grid cell 150. For batch picking and depending on the number of customer orders that need to be fulfilled, the picking mechanism can be instructed to transfer a plurality of the items from the storage container to the dispenser container. Subsequently to transferring the plurality of common items to the dispenser container, the warehouse management system can instruct a robotic load handling device carry the dispenser container to various storage locations of the batch of the plurality of delivery containers that have been identified by the warehouse management system to fulfil a batch of customer orders and dispense at least one of the common items into the delivery containers (steps 52 and 54 in Figure 6).

[0141] As depicted in the illustration shown in Figure 18, the robotic load handling device 30 carrying the dispenser container 58 can be instructed to deposit one or more of the items 64 to each of the batch of the plurality of delivery containers 90 in their respective storage locations in succession in a single operation. At each of the storage locations, the robotic load handling is instructed to pause such that the drive mechanism to open the trap door can be actuated to deposit one or more of the items into the delivery container. Depending on the grid cell position of each of the storage locations of the batch of the plurality of delivery containers, the warehouse management system may determine an optimised route to each of the storage locations of the batch of the plurality of delivery containers identified for batch picking. Optimisation can be based on minimising the cost function to transport the dispenser container to each of the storage locations and could include the shortest travel distance to move to each of the storage locations and / or the fastest time to complete the route to each of the storage locations. Various path optimisation algorithms through application of heuristic techniques known in the art can be used to determine an optimised route path to each of the storage locations of the batch of the plurality of delivery containers, e.g. A* pathfinding algorithm as taught in WO2015 / 155628 (Ocado Innovation Limited). The particular example in Figure 21 show the route taken by the robotic load handling device when depositing at least one item to four storage locations labelled 1, 2, 3 and 4 of the delivery containers.

[0142] Subsequent to the plurality of items being transferred to the dispenser container by the robotic arm in step 150 of Figure 22, the dispenser container 58 is carried to each of the storage locations 1, 2, 3 and 4 in succession and at each successive movement of the dispenser container above each of the batch of the plurality of delivery containers, the drive mechanism to the trap door is actuated to deposit at least one of the items into a delivery container below such that each of the batch of the plurality of delivery containers identified in the batch pick comprises at least one of the items. The illustration shown in Figure 21 is a simplified example of batch picking and it will be appreciated that the number of storage locations for fulfilling a plurality of customer orders for batch picking is not limited to four and can be any number of customer orders greater than two and is largely dependent on the number of customer orders in a given batch pick. For a relatively small number of customer orders in a batch, very few repeated journeys may be needed between the delivery containers and the pick station to fulfil a group of customer orders in the batch to the extent that the customer orders can be fulfilled in a single operation of the robotic load handling device on the track system. It will be appreciated that for a relatively large number of customer orders in a batch repeated journeys may be required between the identified delivery containers in the batch and the pick station to such an extent that the customer orders can only be fulfilled in multiple operations between the pick station and the delivery containers. This may be due to the carrying capacity of the dispenser container and / or the relative size and / or weight of the inventory items. It will be appreciated that the journey to deposit at least one of the inventory items between the pick station and the storage locations of the batch of the plurality of delivery containers can be repeated depending on the number of delivery containers identified for batch picking. In other words, the robotic load handling device can be instructed to move the dispenser container to the pick station to receive the at least one common item from the storage container in the second zone and then travel to a storage location of a delivery container identified for batch picking, and deposit the at least one of the inventory items into the delivery container. This process can be repeated until all of the delivery containers identified for batch picking have been fulfilled with at least one of the inventory items. However, the advantage to deposit the at least one of the inventory items in the dispenser container into each of the delivery container identified for batch picking is the ability to not only reduce the congestion at the pick station but the operation can take place in a single operation of the robotic load handing device to each of the storage locations of the delivery container without the need to return the dispenser container to the pick station for refilling. Moreover, customer orders can be fulfilled in the delivery containers whilst in storage in the grid framework structure that are not accessible by the picking mechanism.

[0143] It will be appreciated that the dispenser mechanism can be the robotic dispenser device discussed above (see Figure 19 and 20). Thus, instead of transferring the inventory items to a dispenser container and a robotic load handling device being instructed to pick up the dispenser container, in an alternative disclosure, a dedicated robotic dispenser device 102 discussed above with a built-in trap door can be instructed to receive the inventory items in the body of the robotic dispenser device at the picking station (see Figure 19). The warehouse management system can apply the same instructions as the robotic load handling device to move the robotic dispenser device on the track system to various storage locations of a batch of the plurality of delivery containers identified for batch picking and deposit at least one of the inventory items into each of the batch of the plurality of delivery containers though an opening in a grid cell as shown in Figure 20. As with the dispenser container discussed above, movement of the robotic dispenser device to each of the plurality of storage locations of the batch of the plurality of delivery containers can be in a single operation in succession or repeated visits to the pick station 106 to a refill the robotic dispenser device 102 with inventory items.

[0144] The robotic dispenser device 102 can be used in conjunction with the dispenser container 58 to fulfil one or more batch of customer orders. The robotic dispenser device can complement the dispenser container to fulfil one or more batches of customer orders. For example, inventory items that are more suited to being carried by the dispenser container can be used to fulfil at least a first portion of a batch of customer orders and inventory items that are more suited to be carried by the robotic dispenser device can be used to fulfil a second portion of the batch of customer orders. Equally, the dispenser container 58 and the robotic dispenser device 102 can complement each other to fulfil different batches of customer orders. In both scenarios, the use of a dispenser mechanism to fulfil customer orders in-situ on the grid framework structure alleviates the congestion around the pick station allowing for a greater number of customer orders to be fulfilled.

[0145] To further free up the grid cells around the robotic arm and thereby, prevent crowding of robotic load handling devices around the robotic arm, the dispenser mechanism can be transferred to a pick station 206 outside of the grid framework structure to be loaded with inventory items for batch picking. In an alternative disclosure, a robotic load handling device operative on the track system can be instructed to carry the dispenser container to the pick station 206 outside of the grid framework structure via at least one port column 152 extending downwardly from a grid cell to the pick station 206. A second robotic load handling device can be instructed to retrieve a storage container from a storage location in the grid framework structure containing inventory items having a particular SKU type to fulfil a group of customer orders for batch picking. The pick station comprises a conveyor system that is arranged with a drop-off zone for receiving the storage container via the at least one port column, a pick-up zone for picking-up the storage container from the conveyor system via the at least one port column and an access zone 154 for accessing the contents of the storage container on the conveyor system. The conveyor system can be arranged to transport the storage container from the supply zone to the picking- up zone via the access zone 154. The at least one port column can comprise a drop-off column 152 that cooperates with the drop off zone for dropping off one or more storage containers and a pick up column 152 that cooperates with the pick-up zone for picking up one or more storage containers from the conveyor system. The drop-off column and the pick-up column can be separate port columns or a single port column as shown in Figures 23(a and b).

[0146] In addition to receiving one or more storage containers, the pick station 206 can be configured to receive the dispenser container 58 via the at least one port column 152. The conveyor system can additionally comprise a drop-off zone (herein referred to as dispenser drop-off zone) for receiving the dispenser container via the at least one port column, a pick-up zone (herein referred to as dispenser pick-up zone) for picking-up the dispenser container from the conveyor system via the at least one port column and a dispenser access zone 158 for gaining access to the dispenser container 58 on the conveyor system. The conveyor system can be arranged to transport the dispenser container from the dispenser supply zone to the dispenser picking-up zone via the dispenser access zone. The dispenser container can be dropped-off to the dispenser drop-off zone of the conveyor system via a dispenser drop-off column 164 and picked up from the dispenser pick-up zone of the conveyor system via a dispenser pick-up column 166. The dispenser drop-off column 164 and the dispenser pick-up column 166 can be a single column or separate columns as shown in Figures 23(a and b).

[0147] The conveyor system can be arranged such that the access zone 154 for accessing the contents of the storage container is adjacent the dispenser access zone 158 to the extent that the storage container and the dispenser container are within easy reach to an operator (picking mechanism) to transfer one or more inventory items from the storage container to the dispenser container. The conveyor system can be configured such that the storage container and the dispenser container can be independently transported to their respective access station and dispenser access station. It will be appreciated that the conveyor system can comprise separate conveyor systems to separately transport the storage container and the dispenser container to their respective access zone and dispenser access zone. The separate conveyor systems can be defined as an inventory conveyor system for the purpose of transporting the storage container to the access zone and a dispenser conveyor system for the purpose of transporting the dispenser container to the dispenser access zone. It will also be appreciated that the picking mechanism for transferring one or more inventory items from the storage container to the dispenser container can be a manual operator 168 as shown in Figures 18(a and b) or a robotic arm (not shown).

[0148] The process for batch picking a plurality of customer orders can follow the same process steps described with reference to the flowchart shown in Figure 6. However, the step of transferring the inventory items to the dispenser container between steps 44 and 46 in Figure 6 occurs outside of the grid framework structure rather within the grid framework structure and can be described with reference to the flowchart shown in Figure 24. In operation, the warehouse management system can instruct a robotic load handling device operative on the track system to pick up a dispenser container and transport the dispenser container to the pick station 170 whereupon the conveyor system transports the dispenser container to the dispenser access station 172. Prior to or subsequently to or simultaneously to delivering the dispenser container to the pick station, the same or a second robotic load handling device operative on the track system can be instructed to pick up a storage container that has been identified by the warehouse management system to contain a plurality of inventory items for batch picking, i.e., contain inventory items to fulfil a consolidated list of customer orders 174, and move the storage container to the access station 176. At their respective dispenser access station and access station, the manual picking mechanism or robotic picking mechanism transfers one or more items from the storage container to the dispenser container 178.

[0149] The loaded dispenser container is subsequently picked up by a robotic load handling device via the dispenser pick-up column 166 and the process of depositing at least one of the inventory items to each of the delivery containers identified for batch picking in step 54 discussed above with reference to the flowchart shown in Figure 6 is repeated.

[0150] In comparison to loading the dispenser container with inventory items by a robotic arm mounted to the grid framework structure (herein referred to as on grid robotic pick), loading the dispenser container outside of the grid framework structure provides the advantage of freeing up one or more grid cells adjacent the robotic arm which in turn, mitigates congestion of robotic load handling devices waiting for a slot to become available on the track system to deposit either a delivery container or storage container for fulfilling a customer order. Moreover, on grid robotic pick can be used in conjunction with batch picking outside of the grid framework structure. For example, on grid robotic pick can complement picking outside of the grid framework structure to fulfil one or more customer orders. Items that are difficult to handle or pick due to the type of end effector on the robotic arm and / or the shape of the item can be transported to the picking mechanism to be picked manually outside of the grid framework structure and items that can be handled or picked by the robotic arm can be transported to the picking mechanism mounted to the track system.

[0151] It will be appreciated that different combinations of the picking mechanism and the dispenser mechanism can be used to batch pick a group of customer orders. For example, instead of the dispenser mechanism containing one or more items transferring one or more of the items to the delivery containers in storage in their respective storage columns, the dispenser mechanism can dispense the one or more of the items to a second dispenser mechanism; the dispenser mechanism being defined as the first dispenser mechanism. The dispenser mechanism could be the dispenser container or the robotic dispenser device discussed above. The first dispenser mechanism can function to buffer the one or more items prior to being dispensed into one or more delivery containers. In all of the different examples of batch picking discussed above, the requirement to transport the delivery container to the picking mechanism has been removed.

Claims

Claims1. A dispenser mechanism for an automated storage and retrieval system, the automated storage and retrieval system comprising a track system for guiding the movement of one or more load handling devices, the track system comprising a plurality of tracks arranged in a grid pattern and forming a plurality of grid cells, and a supporting framework structure comprising a plurality of storage columns, the plurality of storage columns being arranged below the track system and arranged to accommodate a plurality of storage containers and a plurality of delivery containers; the dispenser mechanism comprises: i) a body comprising sidewalls and a bottom wall with an open end for receiving the one or more items, at least a portion of the bottom wall having at least one opening extending through the at least portion of the bottom wall of the body, ii) a trap door for closing the at least one opening; iii) a drive mechanism configured to drive the trap door between a closed position for containing one or more items within the dispenser mechanism and an open position to cause the one or more items to be dispensed from the dispenser mechanism from the at least one opening; iv) a dispenser controller comprising one or more processors and memory storing instructions that when executed by the one or more processors is operable to control the movement of the trap door between the closed position and the open position, wherein the dispenser controller and the drive mechanism forming an electrical load; v) a rechargeable power source for providing power to the electrical load; wherein the body comprises a charge receiving interface electrically coupled to the rechargeable power source and a communication interface, said charge receiving interface being configured to electrically or magnetically couple with a charge providing interface and wherein the dispenser controller is configured to receive instructions to control the movement of the trap door between the closed position and the open position via the communication interface.

562. The dispenser mechanism of claim 1 , wherein the trap door comprises at least one door leaf rotatably mounted to the body of the dispenser mechanism by a hinge mechanism, said hinge mechanism is coupled to the drive mechanism by a gear mechanism operable to control the movement of the at least one door leaf between the closed position and the open position.

3. The dispenser mechanism of claim 2, wherein the gear mechanism comprises a worm gear engageable with a worm wheel such that rotation of the worm gear by the drive mechanism drives rotation of the worm wheel to rotate the at least one door leaf of the trap door between the open and closed positions.

4. The dispenser mechanism of claim 2 or 3, further comprising a sensor system configured to sense the position of the at least one door leaf between the closed position and the open position, and wherein the dispenser controller is configured to control the gear mechanism to control the orientation of the at least one door leaf of the trap door between the closed position and the open position in response to one or more signals from the sensor system.

5. The dispenser mechanism of claim 4, wherein the sensor system comprises a position sensor configured to sense the position of the at least one door leaf at the closed position and / or at the open position and a rotary encoder configured to determine the rotation of the at least one door leaf.

6. The dispenser mechanism of any of the preceding claims, wherein the at least one door leaf comprises a plurality of door leaves, each of the plurality of door leaves being independently moveable relative to each other between the closed position and the open position to open at least a portion of the bottom wall of the dispenser mechanism.

7. The dispenser mechanism of any of the preceding claims, wherein the charge receiving interface comprises at least two charge receiving pads connectable to at least two charge providing pads of the charge providing interface.

578. The dispenser mechanism of any of the preceding claims, wherein the charge receiving interface comprises a receiving coil for inductively coupling with a transmitter coil of the charge providing interface.

9. The dispenser mechanism of any of the claims 1 to 8, wherein the sidewalls and the bottom wall are arranged to form a dispenser container with an open end for receiving the one or more items within the dispenser container, said dispenser container comprises a rim portion extending around at least a portion of the periphery of the open end of the dispenser container, the rim portion comprising one or more openings or depressions for engagement with a grabber device of a load handling device.

10. An automated storage and retrieval system for batch picking of items, comprising i) a grid framework structure comprising a track system for guiding the movement of one or more load handling devices, the track system comprising a plurality of tracks arranged in a grid pattern and forming a plurality of grid cells, and a supporting framework structure comprising a plurality of storage columns arranged below the track system and arranged to accommodate a plurality of storage containers and a plurality of delivery containers; ii) a load handling device comprising a controller configured to control the operation of the load handling device on the track system in response to receiving one or more signals from a master controller; iii) a pick station comprising a picking mechanism configured to pick at least one item from a storage container; and iv) a dispenser mechanism according to any one of the claims 1 to 9 being configured to receive the at least one item from the picking mechanism, wherein the dispenser mechanism is moveable above the track system by the load handling device to deliver the at least one item to at least one of the plurality of delivery containers in their respective storage columns in response to instructions from the controller of the load handling device.5811. The automated storage and retrieval system of claim 10, wherein the load handling device comprises a) a driving assembly configured to move the load handling device on the track system; b) a grabber device configured to releasably hold a storage container from above; and c) a lifting assembly configured to raise and lower the grabber device into and out of the supporting framework structure via the grid cells; wherein the controller is configured to control the operation of the load handling device on the track system by controlling the operation of the driving assembly, the grabber device and the lifting assembly.

12. The automated storage and retrieval system of claim 10 or 11, wherein the picking mechanism is mounted to the track system such that a first grid cell and a second grid cell of the track system are accessible by the picking mechanism.

13. The automated storage and retrieval system according to claim 12, wherein the picking mechanism comprises a robotic arm mounted to the track system.

14. The automated storage and retrieval system according to any of the claim 10 to 13, wherein the grid framework structure further comprises at least one port column, said at least one port column extending downwardly from a grid cell to the pick station through which the load handling device can drop off and pick up storage containers from the pick station, and wherein the pick station comprises a conveyor system comprising a drop-off zone for receiving the at least one of the plurality of storage containers via the at least one port column, a pick-up zone for picking-up the at least one of the plurality of storage containers from the conveyor system via the at least one port column and an access zone for accessing the contents of the at least one of the plurality of containers on the conveyor system, said conveyor system being arranged to transport the at least one of the plurality of storage containers from the drop-off zone to the pick-up zone via the access zone.5915. The automated storage and retrieval system according to claim 14, wherein the conveyor system further comprises a dispenser drop-off zone for receiving the dispenser mechanism via the at least one port column, a dispenser pick-up zone for picking up the dispenser mechanism from the conveyor system via the at least one port column and a dispenser access zone for accessing the dispenser mechanism on the conveyor system, said conveyor system being arranged to transport the dispenser mechanism from the dispenser drop-off zone to the dispenser pick-up zone via the dispenser access zone.

16. A method of batch picking of items in an automated storage and retrieval system according to any of the claims 10 to 15; the method comprising the steps of: i) consolidating a plurality of orders into at least one batch of orders based on each order of the at least one batch of orders comprising an item having an attribute that is common to each order of the at least one batch of orders; ii) moving a storage container containing a plurality of the items having the common attribute to a position adjacent the picking mechanism such that the plurality of the items contained therein are accessible by the picking mechanism; iii) transferring, by the picking mechanism, at least one of the plurality of items to the dispenser mechanism; iv) dispensing, by the dispenser mechanism, at least one of the plurality of items to at least one of the plurality of delivery containers in their respective storage column that is inaccessible by the picking mechanism.

17. The method of claim 16, wherein the plurality of delivery containers and the plurality of storage containers are arranged in one or more stacks of containers; the method further comprising the steps of: v) determining whether one or more of the plurality of storage containers overlay one or more of the plurality of delivery containers in a given stack of containers, and60vi) if one or more of the plurality of storage containers overlay one or more of the delivery containers in the given stack, removing the one or more of the overlaying storage containers from the given stack to expose the delivery container to the track system.

18. The method of claim 16 or 17, further comprising repeating steps (iii) and (iv) to a batch of the plurality of the delivery containers such that each of the batch of the plurality of delivery containers comprises at least one of the plurality of the items.

19. The method of any one of the claims 16 to 18, wherein the picking mechanism in step (iii) is instructed to transfer the plurality of items to the dispenser mechanism, and wherein the dispenser mechanism in step (iv) is instructed to deposit at least one of the plurality of items into each of a batch of the plurality of delivery containers in their respective storage columns in succession until each of the batch of the plurality of delivery containers comprises at least one of the plurality of items.

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