Automated storage and retrieval system climate control

Abstract

A facility has an ambient zone (30); a lower temperature storage space; an intermediate temperature storage space (42); a higher temperature storage space (44); a plurality of HVAC systems (430, 432, 434) for controlling temperature and humidity in the storage spaces; automated equipment for moving material through the storage spaces and presenting the material for fulfillment of orders. The automated equipment moves in an automation zone (50, 52) above and traversing the storage spaces (42, 44).

Description

121577P524PCAUTOMATED STORAGE AND RETRIEVAL SYSTEM CLIMATE CONTROLCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] Benefit is claimed of US Patent Application No. 63 / 853,909, filed July 30, 2025, US Patent Application No. 63 / 772,418, filed March 14, 2025, and US Patent Application No.63 / 726,057, filed November 27, 2024, all entitled “Automated Storage and Retrieval System Climate Control”, the disclosures of which are incorporated by reference herein in their entireties as if set forth at length.BACKGROUND

[0002] The disclosure relates to cold chain distribution facilities with automated storage and retrieval systems (ASRS). More particularly, the disclosure relates to climate control thereof.

[0003] A cold chain (e.g., food) distribution facility has multiple zones at multiple temperatures and humidities for storing respective goods needing such respective environments. Such facilities may be used for various levels of fulfilment / delivery in the supply chain.

[0004] A low level delivery involves fulfillment of individual consumer orders for home delivery. For example, an order may be placed in one or more containers.

[0005] At a higher level of fulfillment, larger containers, pallets, or the like may be used to deliver from a central facility to, for example, a retailer or a local distribution facility.

[0006] In fulfilling a given order (e.g., a given consumer order at a low level or a supply to a distribution center or retailer at higher levels), automated equipment may need to move between the various zones of different temperature and humidity. Additionally, such equipment may operate in other zones for movement, parking, inspection / cleaning, and the like. The temperatures and humidity of the various storage zones and other zones may present the risk of condensation on the equipment. Such condensation may contribute to deterioration of the equipment or contamination of the equipment and the locations it passes through.

[0007] In one example, the separate storage spaces / areas / zones represent separate rooms each with multiple storage locations accessed from above. For example, an ASRS may span several storage zones with storage grid sections in each of the zones. Various examples of storage grids and associated storage / retrieval equipment are shown in US Patent Application Publication No. 2109 / 0031399A1, published January 31, 2019, entitled “Storage Systems, Methods and Containers, by Shaikh et al.; US Patent Application Publication No.121577P524PC2020 / 0290803 Al, published September 17, 2020, entitled “An Automated Storage and Retrieval System” by Austrheim; US Patent Application Publication No. 2023 / 0382642A1, published November 30, 2023, entitled “Container Handling Vehicle with Increased Stability”, by Heggebo et al.; and US Patent Application Publication No. 2023 / 0136087A1, published May 4, 2023, entitled “Section Based Speed Reduction”, by Fagerland. The disclosures of these four publications are incorporated by reference herein in their entireties as if set forth at length.SUMMARY

[0008] One aspect of the disclosure involves a facility comprising: an ambient zone; a lower temperature storage space; an intermediate temperature storage space; a higher temperature storage space; a plurality of HVAC systems for controlling temperature and humidity in the storage spaces; automated equipment for moving material through the storage spaces and presenting the material for fulfillment of orders. The automated equipment moves in an automation zone above and traversing the storage spaces.

[0009] A further embodiment of any of the foregoing embodiments may additionally and / or alternatively include means for allowing the automated equipment to move in the automation zone and traverse the storage spaces while mitigating condensation on the automated equipment.

[0010] A further embodiment of any of the foregoing embodiments may additionally and / or alternatively include means for isolating a portion of the automation zone above the higher temperature storage space from a portion of the automation zone above the intermediate temperature storage space.

[0011] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the means for isolating the portion of the automation zone above the higher temperature storage space from the portion of the automation zone above the intermediate temperature storage space comprises: a thermo-nest between the higher temperature storage space and the lower temperature storage space; and an air knife above the automation zone and positioned to drive an air flow through the thermo-nest.

[0012] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the means for isolating the portion of the automation zone above the higher temperature storage space from the portion of the automation zone above the intermediate temperature storage space further comprises means for driving a recirculating flow upward from the higher temperature storage space through the automation zone and laterally toward the thermo-nest, turning downward to return to the higher temperature storage space adjacent the121577P524PC thermo-nest and then pass within the higher temperature storage space away from the thermonest. A branch from the recirculating flow passes above the thermo-nest and back down through the automation zone into the thermo-nest and a flow exiting the thermo-nest itself branches into a first portion joining the recirculating flow and a second portion returning back to the thermonest.

[0013] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the means for isolating the portion of the automation zone above the higher temperature storage space from the portion of the automation zone above the intermediate temperature storage space further comprises means for driving a recirculating flow away from the thermo-nest, turning downward through the automation zone and into the higher temperature storage space, turning laterally toward the thermo-nest, turning upward to again pass through the automation zone to turn away from the thermo-nest, wherein a branch from the recirculating flow passes above the thermo-nest and back down through the automation zone into the thermonest and a flow exiting the thermo-nest itself branches into a first portion joining the recirculating flow and a second portion returning back to the thermo-nest.

[0014] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the means (preferably the means for allowing the automated equipment to move in the automation zone and traverse the storage areas while mitigating condensation on the automated equipment) comprises: means for homogenizing a condition of the portion of the automation zone above the intermediate temperature storage space with a portion of the automation zone above the lower temperature storage space.

[0015] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the means for homogenizing comprises: means for inducing a recirculating convection flow within the lower temperature storage space; and means for mixing a flow exiting the lower temperature storage space and a flow exiting the intermediate temperature storage space and cooling the mixed flow and directing the mixed flow back to the intermediate temperature storage space.

[0016] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the means for inducing a recirculating convection flow within the lower temperature storage space comprises: a first bank of storage columns; a second bank of storage columns; a first gap between the first and second banks; a first lateral gap between the first bank and a wall separating the lower temperature storage space from the intermediate temperature121577P524PC storage space; a second lateral gap between the second bank and a wall of the lower temperature storage space opposite the first lateral gap; and refrigerant coils for cooling air in the first lateral gap and the second lateral gap.

[0017] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the directing of the mixed flow back to the intermediate temperature storage space comprises passing the mixed flow above the automation zone back toward the higher temperature storage space and then downward through the automation zone back into the intermediate temperature storage space and then, within the intermediate temperature storage space toward the lower temperature storage space and back up toward the automation zone as said flow exiting the intermediate temperature storage space to, in turn, branch into a portion passing within the automation zone over the lower temperature storage space and a portion descending into the lower temperature storage space.

[0018] A further embodiment of any of the foregoing embodiments may additionally and / or alternatively include respective storage grid sections in the lower temperature storage space, the intermediate temperature storage space, and the higher temperature storage space; and rails in the automation zone spanning the storage spaces to allow the automated equipment to traverse the storage spaces.

[0019] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the respective storage grid sections are configured to store bins and the automated equipment is configured to transport said bins.

[0020] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the respective storage grid sections are configured to store bins in a rectangular array of columns.

[0021] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the automated equipment is configured to drive on first and second orthogonal sets of tracks.

[0022] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the automated equipment is configured to reach down into the columns to retrieve or deposit an uppermost bin in a column.

[0023] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the automated equipment comprises a plurality of bots, each hot having: a left pair of wheels and a right pair of wheels for moving in a first direction on first tracks; a front pair of121577P524PC wheels and an aft pair of wheels for moving in a second direction orthogonal to the first direction on second tracks; and a winch system for engaging a bin to raise and lower the bin.

[0024] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, each bot winch system has a gripper plate suspended by four cables or straps and having latching members complementary to latching members of the bin.

[0025] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively: respective lower temperature, intermediate temperature, and higher temperature pick and replenishment areas are respectively associated with the lower temperature storage space, the intermediate temperature storage space, and the higher temperature storage space; the pick and replenishment areas have access to the associated storage space via an aperture in an associated wall of the storage space; the lower temperature pick and replenishment area and the intermediate temperature pick and replenishment area are respectively thermally isolated from each other and from a surrounding environment within the facility; and the higher temperature pick and replenishment area is exposed to a surrounding environment within the facility.

[0026] A further embodiment of any of the foregoing embodiments may additionally and / or alternatively include a pick and load area having outbound transfer stations with direct access to the intermediate temperature storage space.

[0027] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the transfer stations are in respective bays and each bay is associated with a respective outbound loading dock.

[0028] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, there are no outbound transfer stations with direct access to either the low temperature storage space or the high temperature storage space.

[0029] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively: the automated equipment comprises autonomous guided vehicles (AGV); and the automation zone contains charging stations for the AGV above the intermediate temperature storage space.

[0030] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively: a service mezzanine is aside the intermediate temperature storage space; and the charging stations comprise means for registering the AGV and means for electrically coupling to the AGV.121577P524PC

[0031] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively: the charging stations for the AGV above the intermediate temperature storage space are at least five times greater in number than charging stations, if any, above the lower temperature storage space; and the charging stations for the AGV above the intermediate temperature storage space are at least five times greater in number than charging stations, if any, above the higher temperature storage space.

[0032] A further aspect of the disclosure involves, a method for operating said facility, the method comprising: maintaining the lower temperature storage space at a first temperature; maintaining the intermediate temperature storage space at a second temperature; maintaining the higher temperature storage space at a third temperature; and maintaining a portion of the automation zone above the lower temperature storage space at a fourth temperature above the first temperature. In various examples, the fourth temperature may be closer to the second temperature than to the first temperature.

[0033] A further embodiment of any of the foregoing embodiments may additionally and / or alternatively include maintaining humidity control of a section of the automation zone above the higher temperature storage space; and maintaining humidity control of a section of the automation zone above the lower and intermediate temperature storage spaces.

[0034] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the maintaining the lower temperature storage space at a first temperature comprises cooling opposite first and second portions of the lower temperature storage space to drive down passes of air, the down passes passing downward and then turning inward toward each other and then turning upward between first and second banks of storage columns.

[0035] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively: the down passes pass within associated gaps adjacent associated walls of the lower temperature storage space; and additional down passes pass within gaps transverse to said gaps and merge therewith to become one or more up passes between the banks.

[0036] In a further embodiment of any of the foregoing embodiments, additionally and / or alternatively, the: the lower temperature storage space is divided into separate spaces separated by walls; and each of the separate spaces have respective said first and second portions, down passes, and first and second banks.121577P524PC

[0037] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG. 1 is a schematic plan view of a first facility.

[0039] FIG. 1 A is a view of a fulfillment area of the first facility.

[0040] FIG. IB is an enlarged view of a lower temperature storage space of FIG. 1 A.

[0041] FIG. 2 is a first schematic vertical sectional view of the first facility fulfillment area, taken along line 2-2 of FIG. 1 A.

[0042] FIG. 3 is a second schematic vertical sectional view of the first facility fulfillment area, taken transverse to FIG. 2.

[0043] FIG. 4 is a further schematic vertical sectional view of the first facility fulfillment area corresponding to FIG. 3 and showing flows.

[0044] FIG. 4A is an enlarged view of a thermo-nest of FIG. 4.

[0045] FIG. 4B is an enlarged view of a lower temperature storage space of FIG. 4.

[0046] FIG. 5 is a schematic partial top view of a grid in an automated storage and retrieval system (ASRS) of the first facility.

[0047] FIG. 6 is a side view of an autonomous guided vehicle (AGV) of the ASRS.

[0048] FIG. 7 is a front view of the AGV.

[0049] FIG. 8 is a schematic vertical sectional view of a second facility fulfillment area modified relative to FIG. 4.

[0050] FIG. 9 is a plan view showing airflows in the second facility.

[0051] FIG. 10 is a side view showing the grid structure with vertical members supporting the orthogonal sets of tracks or rails.

[0052] Like reference numbers and designations in the various drawings indicate like elements.121577P524PCDETAILED DESCRIPTION

[0053] Discussed further below, multi-zone storage facility automation (handling equipment such as autonomous guided vehicles (AGV), gantry cranes, and the like) moving between zones presents issues of undesirable condensation on such automation. Below are discussed options for configuring the facility to limit opportunities for such condensation.

[0054] FIG. 1 shows a building / facility 1 having an outer wall or envelope 2 within an external environment 29. The building has a receiving area 3 having docks 4 for receiving goods from trucks / trailers 5. FIG. 1 also shows office space 6 and various means 7 for moving goods around. Example means 7 includes forklifts / fork trucks (whether automated or not), pallet jacks, and the like. The example facility includes internal bulk storage spaces 10, 12, and 14 at progressively higher temperatures. The example storage space 10 is a frozen storage space, 12 a chilled storage space, and 14 an ambient storage space. Nevertheless, the ambient storage space may itself be cooled whereas the frozen storage space is well below freezing, and the chilled storage space slightly above freezing. FIG. 1 further shows an example control system 19 which may include one or more computers or similar controllers with one or more processors, memory, storage, and input / output devices. The control system may control operations of the facility 1 and hardware therein and may communicate with external locations for purposes such as ordering inventory replenishment, receiving orders for fulfillment, and general diagnostics.

[0055] These storage spaces are bulk storage spaces with relatively high storage density. For example, the storage spaces 10 and 12 may have stacked pallet floor storage and the ambient storage space 14 may include racking. In this particular example, these storage spaces service a fulfillment area 20 which itself has three corresponding storage spaces discussed below. In one group of examples, the fulfillment area 20 is an e-commerce fulfillment area for deliveries directly to consumers. With such a situation, depending upon the implementation, the facility may be appurtenant to or a portion of a larger facility serving some other purposes such as retail. In such a situation, the storage spaces 10, 12, and 14 may represent the baseline storage spaces for the retail operation and the fulfillment area 20 may be added in an update / renovation. It is within the fulfillment area 20 that the aforementioned undesirable condensation issues are addressed below.

[0056] Nevertheless, the principles discussed may be applied to differing overall facilities 1 and yet differently arranged fulfillment areas 20. Such alternatives include fulfillment not for consumer delivery but, for example, for supplying small retailers.121577P524PC

[0057] The fulfilment area 20 has an external envelope 22 comprising a lateral wall structure 24 and a roof 26 (FIG. 2) and atop a ground surface 28 in an external environment 29. The example interior of the building comprises an ambient zone 30 (not to be confused with the ambient storage zone 44 discussed below) which typically will have some degree of climate control relative to the external environment 29 but within a broad potential range of temperatures and possibly with substantial seasonal or other variation.

[0058] The interior includes volumes / spaces for goods storage and ancillary equipment and activities (e.g., within an inner envelope 32 (having a lateral wall 34 and a ceiling or upper wall 36)). FIG. 1A shows a frozen goods storage space 40 (having individual subspaces 40 A, 40B, 40C), a chilled storage space 42, and an ambient storage space 44 (lower, intermediate, and higher temperature spaces, respectively). The frozen storage space 40 is used for frozen goods and will be at a temperature of 32°F (0°C) or lower, more particularly, 30°F (-1°C) or lower or 28°F (-2°C) or lower with example typical lower limits on such temperatures of -22°F (-30°C) or 0°F (-18°C). As is discussed further below, each of these spaces 40, 42, 44 contains a portion of an automated storage and retrieval system (ASRS).

[0059] The example chilled storage space 42 is used to store non-frozen perishables such as eggs, dairy, meats, produce in the food example.

[0060] The example ambient storage space 44 is used to store non-frozen, relatively non- perishable, goods such as canned / tinned and dry goods in the food distribution example.

[0061] Table I below shows various example controlled and uncontrolled temperature and humidity ranges for various zones.

[0062] In the illustrated example, an automated storage and retrieval grid spans the zones 40, 42, and 44 and has an upper boundary 920 (FIG. 2) that also forms a lower boundary of an automation zone 50, 52. In the example automation zone, automation (e.g., autonomous guided vehicles (AGV) or “bots” 49 in an initial embodiment discussed) selectively access (e.g., store / retrieve individual carriers / storage units (e.g., totes, bins, pallets, or the like) in / from the grid. In the discussed examples, a given piece of storage and retrieval equipment (e.g., the AGV) may operate between zones (e.g., at one time retrieving / delivering something from / to the frozen storage space 40, another time the chilled storage space 42, and another time the ambient storage space 44). For simplicity, in an initial discussed example, “bins” will identify carriers used by the ASRS, “totes” will identify carriers used to deliver orders from the ASRS, and “pallets” will generally identify carriers used to supply the ASRS.121577P524PC

[0063] One particular bin example is a plastic storage container 45 (schematically shown in FIG. 6). An example plastic storage container is a rectangular footprint, open-top, bin. An example ASRS configuration may store stacks of the bins in respective columns of the ASRS grid. The example grid structure has a rectangular array of posts / uprights / columns at nodes of the rectangular array of storage columns. The uprights are joined by crossmembers, diagonal bracing, and the like to maintain the grid from racking and to physically isolate the columns to maintain the stacks of bins aligned and vertical. At the top of the grid cross-members in the two orthogonal directions form tracks for the bots. Often with an ASRS, the two orthogonal directions are respectively associated with rows and aisles of storage. The association of the names “row” and “aisle” with a particular direction is often arbitrary. However, with rectangular containers, it is typical that “aisles” are parallel to the longer dimension of the container footprint.

[0064] FIG. 5 is a top view of the grid showing individual storage columns separated by orthogonal sets of tracks or rails 810 and 812. For purposes of illustration, bins are shown with diagonal lines therethrough so that empty columns 820A lack such a diagonal line and the remaining columns 820B have the uppermost bin in a stack shown with said diagonal line. Example bots 49 can engage and transport individual bins. Commercial examples of such bots are sold by AutoStore Technology AS, Nedre Vats, Norway, under the trademarks RedLine and R5 Pro. The example bot 49 has a winch system 830 for engaging a bin. The example winch system comprises an end effector or fixture 832 (FIG. 6 - also known as a gripper plate) suspended by four cables or straps (e.g. metallic, polymeric or composite) 834 and having latching members (not shown) complementary to latching members of the bin. Example end effector latching members are pawl pairs and example bin latching members are slots. The pawl pairs may be received in the associated slot and expanded to latch and backlock allowing lifting via the cables or straps.

[0065] The example bot has two respective pairs of wheels for engaging adjacent tracks or rails 810 and 812. Thus, it has a forward pair 840 of left and right wheels and an aft pair 842 of left and right wheels so that the forward pair can engage one track or rail 810 while the aft engages an adjacent rail 810 on an opposite side of a row of columns therefrom. Similarly, the bot has a left pair of fore and aft wheels 844 and right pair of fore and aft wheels 846 for engaging in adjacent tracks or rails 812. At least one of the pairs may be raised and / or lowered to allow selective engagement of either with its associated rails to drive in an associated orthogonal121577P524PC direction of the grid. Various conventional bot features are not shown such as one or more electric drive motors for driving the wheels in the two orthogonal directions and one or more electric winch motors for raising and lowering the gripper plate and actuating the pawls; one or more batteries for powering the bot; an internal controller (e.g. computer, microcontroller, or the like); wireless communication equipment (e.g., radios) for communicating directly or indirectly with the control system 19; sensors; power connections for mating with a charging station to charge the batteries; and the like.

[0066] Thus, to access a given bin, a bot may be driven along the top of the grid until its gripper plate is above the column in which the bin is located. The given column may contain a stack of bins potentially up to the level of the top of the grid. An uppermost bin in the column may protrude above the grid but not so far that it cannot be accessed by the bot (e.g., blocking the bot movement but still below the height of the retracted gripper plate). If the target bin is the uppermost in the stack, the bot may simply lower its gripper plate, grip, and lift. The bot may then be driven off to its destination. If the target bin is not the uppermost in the stack, the bot (or multiple bots working in conjunction) may sequentially remove the bins above the target bin until the target bin may be so accessed.

[0067] In the illustrated example, separate sections of the storage grid are located in each of the physically separated zones 40A-C, 42, and 44. However, a track or rail system at the upper boundary 920 aligned with the grids allows the AGV 49 to pass above each zone to the others. Thus, there may be row and aisle tracks or rails covering essentially the entirety of the area within the inner envelope above the zones 40, 42, 44. Depending upon embodiments, the row and aisle rails may be in a single array or there may be spacing discontinuities such as a longer or shorter spacing between rails at a boundary between zones.

[0068] The automation zone is itself divided into sections 50 and 52 via an air curtain 102 (FIG. 3) from an air knife system 100 discussed further below.

[0069] An upper boundary 922 of the automation zone also forms a lower boundary of a hyperspace 60, 62 forming the upper extreme of the conditioned environment within the inner envelope 32. The hyperspace sections 60, 62 are separated by a wall structure 120 with the section 60 generally above the automation zone section 50 and the section 62 generally above the automation zone section 52.

[0070] The sections 42 and 44 are separated from each other by a thermo-nest 70 having respective sections 71 and 72 adjacent the sections 42 and 44, respectively and separated by a121577P524PC wall 73 extending downward from the boundary 920 to a lower gap 74. FIG. 4A shows the section 71 between the wall 73 and a wall 320 separating the storage zone 44 from the storage zone 42. The example wall 320 is directly below the wall 120 and has an upper end separated therefrom by a gap coextensive with the height of the automation zone. The section 72 is between a wall 322 and the wall 73.

[0071] An inner envelope 32 (FIG. 1 A) separates the ambient zone 30 from the storage zones. In the illustrated example, the inner envelope 32 also separates the ambient zone 30 from respective pick and replenishment areas 140 and 142 respectively associated with the frozen storage zone 40 and chilled storage zone 42. A pick and replenishment area 144 for the ambient storage space 44 is a sub-region or zone of the ambient zone 30. Each of the pick and replenishment areas comprises dedicated storage means 141, 143, and 145, respectively. These example storage means comprise racks or shelving for directly holding goods and / or holding carriers (not necessarily ASRS-compatible) containing goods. Typically, the subject goods will have some aspect that renders them less desirable to be stored in the main ASRS locations within the areas 40, 42, and 44. For example, some may require manual processing by a worker. In one specific example for the section 42 and pick and replenishment area 142, romaine lettuce is often freshened with a manual spray of water by a worker.

[0072] For replenishment, the goods may be delivered to the areas 140, 142, and 144 from one or more originating locations outside the areas 40, 42, 44. The originating locations may be external to the facility such as via a loading dock 3 or may be within a broader facility 1 such as alternative climate-controlled storage spaces 10, 12, 14 such as for longer term storage. The pick and replenishment areas 140 and 142 thus, have doors 149 for access by a delivery means such as a forklift 7 (FIG. 1) carrying a pallet.

[0073] The pick and replenishment areas 140, 142, 144 each have a transfer station 146 which provides access to the ASRS within the associated storage space 40, 42, 44 for transferring goods between the pick and replenishment areas and their respective associated storage spaces. The transfer station may thus have a controlled door (not shown) for isolating the respective pick and replenishment areas from their associated storage spaces. For transferring goods, a transfer mechanism (not shown) such as a swing arm will be included in the transfer station.

[0074] In operation, for a transfer to the ASRS, the ASRS may present a bin or other carrier from the example storage grid to a location within the storage space at the transfer station. The121577P524PC example transfer station thus is essentially at even level with the pick and replenishment area (typically near ground level). With such a bin in position, the control system may open the door and the transfer mechanism (e.g., swing arm) may shift the bin through the door to be accessed by the worker in the pick and replenishment area. For replenishment, the worker may fill or top off the bin with fresh goods (e.g., directly from a pallet or from the temporary storage 141, 143, 145). After the worker has done so, the control system may retract the transfer mechanism and close the door. The control system may then move the AGV to place the bin back in the storage grid in that particular storage space 40, 42, 44.

[0075] In various examples, the control system 19 may further monitor some or all aspects of inventory. This involves maintaining databases of goods and their locations.

[0076] The example database may be used to update and store the following data: receipt information for inventory inducted into the system; date and time the receipt information was validated; date and time of any validation during inspections on the inventory; location of stored inventory; lot codes and expiration dates of stored inventory; identification of individual carriers / storage units and inventory stored within; status of inventory within the carriers / storage units (e.g., reserved, allocated, hold); quantity of each unique inventory item at carrier / storage unit and system levels; dimensional and weight specifications for each unique inventory item; storage unit level and qualities per each unit level as needed (e.g., case, carton, each); quality assurance level of inventory within the carriers / storage units; order information (e.g., customer information, order ID, order received date, order picked date, order shipped date, order delivery date); order contents (e.g., line item information, quantity per line item, special order requirements, special packaging requirements);order processing information (e.g., station order was processed, person who picked the order, shipping dock, out of stock / order shorts); order delivery route information (e.g., route stop sequence, order container per stop and ID, delivery special instructions); order returns information (e.g., customer information, order ID, return received date); and order labeling information.

[0077] This example database tracks the complete life cycle of inventory, order processing, delivery, and returns for all orders processed within the warehouse. This may facilitate efficient operation of the operational processes within the warehouse. An example is knowing that inventory is available and within expiration dates before a customer is allowed to order an item. Once a customer places an order, that stock is reserved for that order and then allocated once the order starts to be processed. Upon completion of the picking for each line item in the order, the121577P524PC inventory is updated for allocation to the next order. Accurate inventory levels within the warehouse support adequate stock replenishment to ensure all items are available for customers to order. Knowing expiration dates and lot codes may ensure the customer does not receive expired product, or even worse quarantined product.

[0078] Knowing the location of unique inventory within carriers / storage units allows assigning tasks to automation to retrieve and deliver the container to the pick stations to allow orders to be fulfilled. These tasks may be sequenced to fulfill each order before proceeding to the next. Orders can be grouped to allow multiple orders to be processed to improve efficiency of the system.

[0079] Expiration dates and lot codes allow the system to deplete old stock before newer stock. Lot codes will also be used to quarantine product as needed for various reasons.

[0080] For example, during transfer of goods at each stage, the workers or automation may scan optical codes (e.g., bar codes or QR codes) or RFID chips / transponders. For example, when loading a bin from a pallet or the like at one of the transfer stations 146, the worker may manually scan each good as it is transferred. This may be consistent with a baseline inventory control system.

[0081] Similarly, in an order fulfillment situation, the control system may control an AGV to present a bin at the appropriate transfer station 146 whereupon the worker may load goods from storage 141, 143, or 145 as with the replenishment scenario.

[0082] The control system 19 may limit the quantity of AGV 49 trips to the frozen storage space 40 per a configurable time duration. This is done to limit the effects of the freezer temperatures on the AGV 49 storage bin handling device. Such effects may include causing mechanical binding (e.g., due to one or more of lubricant thickening and differential thermal expansion) and cooling to the point where condensation may occur upon transit to another zone. Upon reaching the set limit of trips to the freezer 40 for a specific AGV 49, that AGV will be limited to intermediate zone 42 or higher temperature zone 44 movements only for a preset amount of time (restriction time). Upon reaching the preset restriction time, the AGV 49 will be released to be assigned movements to the zone 40 again. The amount of trips per time duration will be configured based on the zone 40 operating temperature range.

[0083] The example frozen replenishment area 140 has its own dedicated HVAC unit keeping it cool by discharging heat to the ambient zone 30.121577P524PC

[0084] The example chilled pick and replenishment area 142 also has its own dedicated HVAC unit keeping it cool by discharging heat to the ambient zone 30.

[0085] The ambient storage manual pick and replenishment area 144 lacks a dedicated HVAC unit.

[0086] Additionally, FIG. 1A shows the ambient zone 30 as including a warehouse area 30A storing empty order totes 150. A conveyor 152 extends within the ambient zone 30 along the front wall section of the ambient storage zone 44 and then into a pick and load area 160 in front of the chilled storage zone 42. Here, operators load goods into totes and transfer them to outbound delivery vehicles (trucks and / or trailers shown as trucks in the example). In an example illustration, the pick and load area 160 is isolated from the ambient zone 30 by full height walls. In the example, the pick and load area is divided into separate bays 160A, 160B, 160C, each associated with a separate loading dock for an associated truck. The operator may receive goods from the ASRS and place them in respective totes which are then passed outward along conveyors 166 to respective trucks 164 at the associated dock 162. For this purpose, each of the bays 160A-160C includes a transfer station 167. The transfer stations 167 may be similar to the transfer stations 146 described above.

[0087] In addition to providing space and means (e.g., rails in the example) for moving the automation between the various storage zones, the automation zone may contain locations for performing various functions relative to the automation. For example, with battery-powered AGV 49, there may be charging stations 200 (FIG. 2). There may be areas 210 for technicians 211 to perform service on the AGV (e.g., cleaning, maintenance, and / or repair). In the FIG. 2 example, a service mezzanine 210 is provided above the chilled storage pick and replenishment area 142. In the example, this comprises a floor 220 recessed below the boundary 920 with a service grid 222 raised above the floor and representing one or more pairs of rails contiguous with the rail array at the top of the ASRS grid so as to allow an AGV to be driven into the service area 210 at a height above the floor 220 effective to allow easy technician access. FIG 1 A shows a retractable safety gate 212 between the mezzanine 210 and the automation zone area directly above the chilled storage zone 42. This example gate is effective to prevent uncommanded or otherwise adverse movement of an AGV into the service mezzanine when the gate is closed. The gate may be formed as a bar or other structure which allows thermal and air communication so that the maintenance area may essentially be at the same conditions as the adjacent portion of the automation zone above the chilled storage zone 42.121577P524PC

[0088] As discussed further below, this location of the service area 210 limits opportunities for condensation to occur. This limitation is relevant both to AGV entering the service area 210 and AGV exiting the service area. For similar avoidance of condensation, the charging stations 200 are also all located above the chilled storage zone 42. If the charging stations were above the frozen storage zone 40, the AGV would cool to the point where condensation would immediately form upon driving to the ambient storage zone 44. However, if the charging stations were above the ambient storage zone 44, energy efficiency would be lost when fully charged but warm AGV moved into the chilled and frozen storage zones.

[0089] Example charging stations comprise hardware for the AGV to automatically engage for charging (e.g., not a mere electrical outlet that a user manually plugs the AGV into). Example such hardware includes a docking station with AGV presence sensor, electrical contacts and communication interface. The docking station may include hardware for physically guiding the AGV into a specific charging location and registering it in that location (e.g., tapering track). The example present sensors are photo eyes or magnetic switches. The electrical contacts (for charging) and the communication interface may be on separate connectors or a single connector. These may all be in communication with the control system 19. The electrical contacts and communication contacts may be fixed and become engaged when the AGV drives into place, or they may be automatically movable to mate with corresponding contact / connectors on the AGV which is via a robotic arm or a simple linear extension mechanism. Alternative hardware may be induction charging pads instead of charging contacts and may include wireless communication. An alternative to recharging is a battery exchange station which may be otherwise similar in terms of engagement and communication but wherein a robotic arm or other removes the installed battery and replaces it with a charged battery. The removed battery may be then deposited in a charging location by the arm or other actuator and itself recharged for subsequent reinstallation in an AGV.

[0090] FIG. 3 shows example positioning of HVAC system components. FIG. 4 shows air flows associated with such components. Example HVAC cabinets 400A-400C (FIG. 1A) are respectively associated with the frozen storage sub-zones / sub-areas 40A-40C. Each HVAC cabinet 400A-400C contains portions of a vapor compression system (e.g., a compressor and heat rejection heat exchanger and associated fans) for passing supply air via duct 410 to the heat rejection heat exchanger and rejecting return air via duct 412 heated by the heat rejection heat exchanger. A similar HVAC cabinet 400D similarly services the frozen replenishment area 140.121577P524PCThe respective vapor compression systems have heat absorption heat exchangers or coils 408 (FIG. 3) in the respective frozen storage spaces 40A-40C and frozen replenishment area 140. In this example, they are along the frozen storage side of a wall 300 separating the chilled storage space 42 from the frozen storage space 40 and along an opposite outboard lateral wall section 302 of the lateral wall 34 and along walls orthogonal thereto including walls 310 separating the sub-zones 40A-40C from each other and outboard walls parallel thereto (FIG. IB). Expansion devices may be local to the coils 408. FIG. 4 shows unnumbered refrigerant supply and return lines to / from the coils. The example coils 408 are refrigerant-air heat exchangers without forced air (e.g., without direct fan-forced air). As discussed below, convection flows are relevant. FIG. 3 further shows a further HVAC cabinet 402 delivering refrigerant to a heat rejection heat exchanger 420 generally centrally in the hyperspace section 60 just below the ceiling 36. The example zones 42 and 44 lack corresponding heat exchangers / coils 408 and are, instead, cooled by separate forced air cooling systems.

[0091] The coils 408 (FIG. 4) may be routed at specific levels within the associated frozen storage spaces 40A-40C. Each of the levels may be temperature controlled independently. There may be a set of temperature sensors 80 at the same location as each level of coils 408. These sensors will be used to get data points specific to each coil level within the respective frozen storage spaces 40A-40C. These data points will be saved within the database in the storage and memory of the control system 19. Based on the real time data at the preselected data points, the control system 19 will control the HVAC system to adjust the temperature up or down as needed via the HVAC units of cabinets 400A-400C.

[0092] FIG. 3 also shows HVAC units 430 and 432 positioned atop the conditioned area respectively atop the hyperspace sections 60 and 62. The HVAC unit 430, specifically, is above frozen storage space 40. Both units 430 and 432 are make up air (MUA) / variable air volume (VAV) units with air supply and return ducts from / to the air external environment. These are self-contained vapor compression system units with respective compressors, heat rejection heat exchangers, expansion devices, and heat absorption heat exchangers and respective fans for driving air flows across their heat exchangers. Another HVAC unit with MU AV AV 434 is positioned on the roof 26 in communication with the ambient environment 30 above the conditioned environment.

[0093] In the illustrated example, the storage grid may include a single continuous structure in each of the zones 42 and 44. Some erstwhile storage columns may be lost from such grids for121577P524PC purposes such as accommodating building support columns or passing utilities (e.g., electrical power and fluids). In distinction, the storage grid structures in each of the frozen zone sections 40A-40C may be divided into two banks 520, 521 (FIGs. IB and 4B) to permit an air up flow 624 (discussed below) in a gap 530 between the banks. Similarly, opposite the gap there are respective outboard / peripheral gaps 531, 532 at the opposite side of each of the two banks and 533, 534 (FIG. IB) at the transverse sides of the banks to accommodate air down flow / down pass 620, 621.

[0094] Additionally, the two banks may each include a raised platform or platforms / spacers 540 (discussed below) to allow air from the respective down pass to flow transversely 622, 623 beneath the columns of stacked bins and then form the up pass 626, 627. In the example, an optional dividing wall 541 splits the central gap 530 into two sub gaps 530-1, 530-2 and thus splits the up pass flow into two branches that can merge at the top of the dividing wall. Symmetry allows operation without the dividing wall. However, the dividing wall may accommodate a variety of asymmetrical situations and enhance flow in those situations. There may thus be a similar gap between the platforms or a platform structure may be provided with openings along the gap.

[0095] Platforms advantageously do not merely support but also act as a baffle to locally block airflow to limit any flow up through vacant columns. Thus, each platform may advantageously block at least 75% of the cross-section of the associated column.

[0096] In some modular situations, the platform for each bank is itself an assembly of platform segments 544 which may be sized to correspond to one or more columns of the grid. Examples of such modular platforms are sold as the “Bin Spacer” (not to be confused with the same manufacturer’s use of the term for internal bin dividers) AutoStore AS, Nedre Vats, Norway. Example segments 544 are formed in a table-like format with respective tops 545 and a plurality of legs 546. Example platform planforms are generally rectangular with a leg at each corner. Gaps between the legs provide for the air flow. As noted above, the tops may serve to locally block air flow in vacant columns and thus may block at least 75% of the cross-section of the associated column. The particular “Bin Spacer” product is configured to exist independently of the grid structure. Thus, the bin spacer may be placed in a column of an otherwise complete grid to space the lowermost bin in any stack above a floor surface. The bin spacer may have features complementary to the gripper plate and thus similar to those of the associated bins to allow bots to deposit the spacers at the bottom of empty columns. This allows selective location121577P524PC of spacers within any grid. Alternative platforms, however, may be less independent and may even include raised floor structures supporting the grid having appropriate openings for passing the airflows discussed herein. The platforms may thus fit within a grid of uprights. In one example, there is one upright at the corner of each cell with adjacent cells sharing uprights.

[0097] The intermediate and higher temperature zones 42 and 44 may have similar platform structures for accommodating flows beneath the columns and similar peripheral gaps for accommodating down pass flows but, as discussed further below, also up pass flows.

[0098] FIG. 4 shows air flows associated with the frozen storage coils 408, evaporator 420, HVAC units 430&432, and air curtain 100. FIG. 4 shows generally recirculating loop flows 600, 602 in the frozen storage zone 40, 604 in the chilled storage zone 42, and 606 in the ambient storage zone 44. There are key interactions of these flows. In the particular transverse sectional view with frozen to the right, ambient to the left, and chilled between, the recirculation in the loop 600 is generally clockwise, 602 counterclockwise, 604 counterclockwise, and 606 clockwise. In the loops 600, 602, the coils 408 create convective down passes 620, 621 along the associated walls 302, 300 and similar down passes (not shown) in gaps 533, 534 along dividing walls 310 and outer walls of the zone 40 parallel to the dividing walls. Flows turn 622, 623 inward near the ground floor and start to warm. This warming causes the convection currents to rise in the center of zone 40 away from the coils 408 passing upward through the gap 530 in up passes 624, 625 more centrally within the ASRS sections within the respective frozen zone sections 40A-40C. These illustrations are schematic. There may be multiple layers of up passes within the ASRS between the walls 300 and 302. Additionally, the up passes from the two loops may effectively merge in the center.

[0099] Terminal portions / branches 626, 627 are the warmer portions of the convection current and these warmer up passes exit frozen storage zone passing into the automation zone section 50 ultimately merging with flow from the chilled zone as is discussed further below. Branches 628, 629 are the convection currents that are still cold enough to complete the recirculation of the respective convection loop 600, 602. Additionally, a make up flow 647 from the chilled zone is also discussed below.

[0100] Recirculation of the flow 604 in the chilled zone 42 is more actively driven. In general, flow 640 from the HVAC unit 430 further passes through the evaporator 420 near the top of the hyperspace to pass as 641 from over the frozen zone 40 to over the chilled storage121577P524PC zone 42 toward the wall 120. This helps actively drive the recirculation of a leg 650 of the loop 604 below.

[0101] Blocked by the wall 120 and, as discussed below, partially driven downward by / through the air curtain unit as 642, a minority portion 643 of this flow air curtain flow then proceeds downward along the chilled zone wall 320 of the thermo-nest 70 merging with a downwardly convecting leg 651 of the loop 604 turning downward from the leg 650. This merged flow 644 then passes laterally as 645 along the floor. As 645 warms, convection will cause this warmer air to start to flow upward. As this convection starts, flow 646 rises up along the chilled zone side of the wall 300. Upon reaching the top of the wall 300, a portion 647 of this chilled flow will become exposed to the lower temperatures of the frozen zone and convect downward as a make up flow in the down pass 621 of the loop 623 to eventually merge along the up passes 624, 625. A remainder 648 of this chilled zone up pass 646 is then driven laterally over the frozen zone via the fan forcing of the HVAC unit 430 and evaporator 420 to merge with the flows 626, 627 exiting the frozen zone and, in turn, pass upward along the wall 302 as 649, then turning inward to become 650.

[0102] The ambient loop 606 includes a down pass 660 along the ambient zone side of the thermo-nest 70. This flow may have a combined forced air and convective motivation with the HVAC unit 432 providing some fan forcing via flow 670 in similar fashion to the driving of the loop 604 by the units 430 and 420. The flow turns outward 661 along the floor. As 661 warms, convection will cause this warmer air to start to flow upward. As this convection starts, flow 661 rises in an up pass 662 along the wall 330 opposite the thermo-nest. The up pass passes through the space 52 and into the space 62, then passing 663 near the ceiling. The cooler portion of 663 will sink as 664 and pass downward to at least partially repopulate the down pass 660. Another portion 666 merges with the forced flow 670. The resulting combined flow 668 is ultimately deflected downward by the wall 120 and toward the entrance / inlet to the thermo-nest section 71 near the wall 120. As is discussed further below, the thermo-nest itself has a down pass 680 along the section 71 then turning upward to an up pass 682 along the section 72 to emerge from an outlet. A portion 684 of this up pass flow 682 turns into the ambient storage zone 44 and merges with the flow 664 to repopulate the down pass 660. Another portion 685 recirculates back to the inlet of the section 71. Additionally, a majority portion 669 of the air curtain flow also merges with the flows 666 and 685 at the inlet to the section 71 to populate the down pass 680.121577P524PC

[0103] Throughout the facility, there may be temperature and humidity sensors used to generally maintain various zones / areas at desired conditions. A circle and a triangle are used to show example position of a temperature sensor 80 (e.g., thermocouple or an RTD (resistance temperature sensor)) and humidity sensor 81 (e.g., capacitive) pair. Also, a small square is used to show dehumidifiers 82. Example dehumidifiers are desiccant dehumidifiers.

[0104] In an example RTD, the resistance of the device is proportional to temperature. Example capacitive humidity sensors contain a humidity probe that uses a capacitor made of two electrode layers with a dielectric material in between. The dielectric material absorbs moisture from the air, which increases the capacitance of the probe. Example desiccant dehumidifiers use a desiccant material and a heating element to absorb moisture. The moisture extracted from the air will drain from the dehumidifier into the facility’s drain system. Additionally, humidifiers may be present such as integrated within the various HVAC units / subsystems. In an example drum humidifier, as air passes through the wick, some of the water evaporates and creates moisture. The drum will present the water via a metal mesh. This will be installed directly to the HVAC system to allow the forced air to pass through humidifying the air.

[0105] As noted above, the control system 19 collects the information gathered from the temperature sensors 80 and the humidity sensors 81 to measure the real time values for temperature and humidity at their respective locations. The control system compares these values to the min and max values in the database to identify current status of the environment within the locations 30, 40, 42, 44, 50, 52, 60 and 62. Based on the real time data at the preselected data points, the control system 19 will cause the HVAC system to adjust the temperature up or down as needed.

[0106] The control system 19 will also control humidity. If the humidity needs to be raised, the HVAC unit humidifiers 433 will raise the humidity as needed. If the humidity needs to be lowered, the dehumidifier 82 close to the humidity sensor 81 that showed excess humidity will activate and lower the humidity until the local sensor 81 registers an acceptable level. The dehumidifiers 82 may be located near humidity sensors 81 at specific locations at floor level. This is done because humidity is heavier and will sink within the locations 30, 40, 42, 44, 50, 52, 60 and 62.

[0107] The database will maintain the history of each temperature sensor 80 and each humidity sensor 81. This database will contain the temperature and humidities for each sensor along with a date and time stamp for each reading. The cadence of recording these readings will121577P524PC be adjustable at a sensor level. As data is gathered, trending for these data points will be used to calculate and fine tune operational settings of the HVAC system improving the efficiency of these systems over time. Seasonal trends will be established and stored in the database. The HVAC system will adjust to accommodate seasonal control parameters as needed. The control parameters will be warehouse site specific.

[0108] Table I below provides examples of such controlled conditions. This may all be done via a central control system such as a microcomputer, microcontroller, or other control system and some or all components may be local or remote (e.g., cloud-based controls). Table I is divided into Tables IA and IB in Fahrenheit and centigrade, respectively.

[0109] Example 1 is a grocery facility where zone 40 contains frozen fruits and vegetables, meat, seafood, ready to eat meals, desserts, baked goods, and snacks, zone 42 contains dairy products, meat, seafood, produce, deli items, beverages, and refrigerated non-frozen ready to eat meals, and zone 44 contains packaged foods, beverages, paper products, cleaning supplies, personal care items, pet supplies, and electronics.

[0110] Example 2 is a pharmaceutical facility. Pharmaceutical products have different product classifications with varying temperature sensitivities, requiring distinct storage conditions to maintain the specific products results. The example in Table I below runs the example different zones or sub-zones (40A, 40B and 40C) at three different temperature ranges. In the particular example of Table I, zone 40 is subdivided into progressively colder compartments / zones from 40A down to 40C. This may be due to differing requirements of the products stored. These products can have the same general description with different storage temperature requirements. Thus, each of the sub-zones within zone 40 may contain vaccines, biologies, blood products, clinical trial material, and specialty medications. Zone 42 may also contain vaccines, biologies, blood products, clinical trial material, and specialty medications, and zone 44 contains oral medications, topical products, medical supplies, OTC (over the counter) medications, and nutritional supplements.121577P524PCTable IAEnvironmental Conditions121577P524PCTable IBEnvironmental Conditions121577P524PC

[0111] In use, temperature and humidity in the locations 30, 40, 42, 44, 50, 52, 60, and 62 may be controlled to within said example limits via operation of the various HVAC units, dehumidifiers, and the like. For example, control may target a nominal value within the identified range. Or, control may use such ranges or subranges therewithin as limits, allowing drift until a limit is reached before corrective action is taken.

[0112] Dehumidifiers (noted above) are particularly desirable in the areas that automation (e.g., AGV 49 in the example) exists or has direct access to. The system is able to add and remove humidity depending on current environmental conditions.

[0113] The humidifying and dehumidifying process described below will operate to maintain a humidity that is within the ranges described in Table I. In the example, any humidity level that is within the ranges as described within Table I for each controlled area (42, 44, 140 and 142) is acceptable. Control may maintain such levels.

[0114] For the area 140 and 142 HVAC system, the control system 19 collects the information gathered from the temperature sensors 80 and the humidity sensors 81 to measure the real time values for temperature and humidity at their respective locations. The control system compares these values to the min and max values in the database to identify current status of the environment. Based on the real time data at the preselected data points, relative to temperature, the HVAC system will adjust the temperature up or down as needed. Relative to humidity, if the humidity needs to be raised, the HVAC systems humidifier will raise the humidity as needed. If the humidity needs to be lowered, the dehumidifier 82 close to the humidity sensor 81 that showed excess humidity will activate and lower the humidity until the local sensor 81 registers an acceptable level. The dehumidifiers 82 will be placed near humidity sensors 81 at specific locations at floor level. This is done because humidity is heavier and will sink within the locations 140 and 142.

[0115] Areas 140 and 142 are independent of areas 40 and 42 to reduce the effect of warm air and warm inventory entering through access doors 149. Addition of warm air and inventory adds capacity requirements to the HVAC system to compensate for the influx of the warmer air and inventory. These smaller areas will allow easier recovery if the HVAC system as these operations occur. Once inventory has been brought to environmental requirements, it can then be inducted into the cube ASRS via the transfer stations 146. This design will improve the operational control of temperature and humidity in areas 40 and 42.121577P524PC

[0116] To maintain a specific humidity range in a warehouse, one or more HVAC systems may be equipped with industrial humidifiers 433 and dehumidifiers 82 which can effectively add needed moisture or remove excess moisture from the air, allowing for precise humidity control in large spaces like warehouses.

[0117] To raise humidity, each of the HVAC systems 430 and 432 may integrate a humidifier 433 such as a rotary drum humidifier. These HVAC systems trigger the addition of moisture to the air flowing out of the HVAC system (430 and 432). The amount of moisture added will be decided by the HVAC controller within the HVAC system (430 and 432) that will utilize the information provided by the humidity sensors 81. When the humidity sensor(s) 81 reach(es) a set high level of humidity, the controller will shut down the humidifier. With multiple sensors in a zone appropriate polling techniques may be used or control may be made to bring humidity sensed by all to within the target range of Table I.

[0118] The dehumidifiers 82 will be utilized to lower the moisture within the controlled areas 42, 44, 140 and 142. These dehumidifier systems are triggered to remove moisture within the controlled areas 42, 44, 140 and 142. The amount of moisture removed will be decided by the HVAC controller within the HVAC system 430 and 432 that will utilize the information provided by the humidity sensor(s) 81. The dehumidifying signal will be sent to the dehumidifier by the HAVC system controller. When the humidity sensor(s) 81 reach(es) a set low level of humidity, the associated humidifier will be shut down. The dehumidifier(s) will only engage when moisture needs to be removed. The dehumidifiers 82 may be located in lower areas of the controlled areas 42, 44, 140 and 142. This is done because humid air is heavier and will sink within the controlled areas 42, 44, 140 and 142.

[0119] FIGs. 8 and 9 show a facility modified relative to that of FIG. 4 except in that the circulation direction of the FIG. 8 recirculating flow / loop 606 is reversed to become 606'. Ambient group 606' leg 662' along the wall 330 opposite the thermo-nest is an up pass rather than the FIG. 4 down pass. Similarly, this leg turns inward to become a leg 661 ' extending along the floor toward the thermo-nest and, in turn, turning upward to become an up pass 660' along the ambient zone side of the thermo-nest. In the recirculating loop 606', the leg 660' passes up into the ambient zone and merges with a flow 684' (described below) to become a flow 664'. Flow 664' splits in the space 62 above with a branch leg 663' turning outward and then ultimately turning downward forming the leg 662'. Similarly, a branch 666' turns back toward the thermo-nest and downward to provide a similar flow 608 entering the thermo-nest.121577P524PC

[0120] The net flow entering the thermo-nest again comprises that flow 608 and the branch 685 branching from the flow / leg 682. In distinction to the branch 684 of FIG. 4, the branch 684' passes upward, merging with 660' to form the leg 664'. To drive the circulation of the loop 606', the orientation of the HVAC unit 432 is reversed relative to FIG. 4 to direct its output flow 670' away from the thermo-nest to merge with the flow 663' to form the flow 662'. FIG. 9 shows a system layout wherein there are two HVAC units 420, two HVAC units 432, and one HVAC unit 430. This example distribution functions to establish the flows for each temperature controlled area and maintain the required temperature and humidity ranges. For zone 44, HVAC units 432 generate and maintain the air flow direction within the zone. The quantity and location of the units will be site specific. For this example, a single HVAC unit 432 is shown. The HVAC unit flows will be directed by diffusers 450. HVAC unit 432 is shown having two diffusers and each example diffuser may have two independent adjustable deflectors (not shown). These diffusers / deflectors will be used to fine tune the flows from the HVAC unit 432 creating four flows 670'. As described prior, the flows 670' will merge with flows 663'. The flow arrows 666' and 663' show the general flow at the ceiling level of zone 44.

[0121] Additionally, FIG. 9 shows the HVAC unit 430 configured to work in conjunction with evaporator 420 for the chilled zone 42 and the chilled hyperspace above zone 40. In general, flow 640 from the HVAC unit 430 further passes through the evaporator 420 near the top of the hyperspace to continue as flows 641 from over the frozen zone 40 to over the chilled storage zone 42 toward the wall 120., HVAC units 430 and evaporator 420 generate and maintain the air flow direction within the zones. The quantity and location of the units will be site specific. For this example, a single HVAC unit 430 and a single evaporator unit with four heat exchangers is shown. The HVAC 430 flows will be directed by diffusers 642. HVAC unit 430 is shown having two diffusers and each diffuser may have two independent adjustable deflectors (not shown). These diffusers / deflectors will be used to fine tune the flows from the HVAC unit 430 creating an example four flows 640. As described prior, the flows 640 will merge with flows 641 as they pass through the evaporator 420 then merge with flows 650. The flow arrows 650 and 649 show the general flow at the ceiling level of zone 42 and 40.

[0122] In the schematic illustrations and associated reference numerals may alternatively schematically identify airflows, airflow paths, and branches thereof alternatively or simultaneously.121577P524PC

[0123] FIG. 10 shows uprights 813 which may be located at the junctions of the tracks or rails 810, 812 of FIG. 5. The uprights can thus act as a stud wall holding up the track / rails while also bounding corners of the associated storage columns. Internal walls may be integrated with a row (in either direction) of the uprights. Thus, for example, the walls 300, 320, 73, and 322 may be so supported by the grid and may be formed from insulated panels. Optionally, however, the walls 73 and 322 may lack insulation because they bound a space effectively within higher temperature zone and heat transfer from the flow leg 660 would not have substantial detriment. The walls 310 separating the zones 40A, 40B, and 40C may similarly be formed as insulated walls integrated with an associated group of uprights. This insulation helps maintain temperatures if one of such zones is, for example, out of service.

[0124] The use of “first”, “second”, and the like in the following claims is for differentiation within the claim only and does not necessarily indicate relative or absolute importance or temporal order. Similarly, the identification in a claim of one element as “first” (or the like) does not preclude such “first” element from identifying an element that is referred to as “second” (or the like) in another claim or in the description.

[0125] Where a measure is given in English units followed by a parenthetical containing SI or other units, the parenthetical’s units are a conversion and should not imply a degree of precision not found in the English units.

[0126] One or more embodiments have been described. Nevertheless, it will be understood that various modifications may be made. For example, when applied to an existing baseline facility configuration or use, details of such baseline may influence details of particular implementations. Accordingly, other embodiments are within the scope of the following claims.

Claims

121577P524PCCLAIMSWhat is claimed is:

1. A facility (1) comprising: an ambient zone (30); a lower temperature storage space (40); an intermediate temperature storage space (42); a higher temperature storage space (44); a plurality of HVAC systems for controlling temperature and humidity in the storage spaces; and automated equipment (49) for moving material through the storage spaces and presenting the material for fulfillment of orders; wherein: the automated equipment moves in an automation zone (50, 52) above and traversing the storage spaces.

2. The facility of claim 1 further comprising: means for allowing the automated equipment to move in the automation zone and traverse the storage areas while mitigating condensation on the automated equipment.

3. The facility of claim 2 wherein the means comprises: means (70, 100) for isolating a portion (52) of the automation zone above the higher temperature storage space from a portion (50) of the automation zone above the intermediate temperature storage space.

4. The facility of claim 3 wherein the means for isolating the portion of the automation zone above the higher temperature storage space from the portion of the automation zone above the intermediate temperature storage space comprises: a thermo-nest (70) between the higher temperature storage space and the lower temperature storage space; and an air knife (100) above the automation zone and positioned to drive an air flow through the thermo-nest.29121577P524PC5. The facility of claim 4 wherein the means for isolating the portion of the automation zone above the higher temperature storage space from the portion of the automation zone above the intermediate temperature storage space further comprises means for driving a recirculating flow (606) upward from the higher temperature storage space through the automation zone and laterally toward the thermo-nest, turning downward to return to the higher temperature storage space adjacent the thermo-nest and then pass within the higher temperature storage space away from the thermo-nest, wherein a branch (666, 608) from the recirculating flow (606) passes above the thermo-nest and back down through the automation zone into the thermo-nest and a flow (682) exiting the thermo-nest itself branches into a first portion (684') joining the recirculating flow and a second portion (685) returning back to the thermo-nest.

6. The facility of claim 4 wherein the means for isolating the portion of the automation zone above the higher temperature storage space from the portion of the automation zone above the intermediate temperature storage space further comprises means for driving a recirculating flow (606') away from the thermo-nest, turning downward through the automation zone and into the higher temperature storage space, turning laterally toward the thermo-nest, turning upward to again pass through the automation zone to turn away from the thermo-nest, wherein a branch (608) from the recirculating flow (606) passes above the thermo-nest and back down through the automation zone into the thermo-nest and a flow (682) exiting the thermo-nest itself branches into a first portion (684) joining the recirculating flow and a second portion (685) returning back to the thermo-nest.

7. The facility of claim 2 or any one of claims 3 to 6 wherein the means comprises: means for homogenizing a condition of the portion of the automation zone above the intermediate temperature storage space with a portion of the automation zone above the lower temperature storage space.

8. The facility of claim 7 wherein the means for homogenizing comprises: means for inducing a recirculating convection flow (600, 602) within the lower temperature storage space; and30121577P524PC means for mixing a flow (626, 627) exiting the lower temperature storage space and a flow (646) exiting the intermediate temperature storage space and cooling the mixed flow (649, 650, 651) and directing the mixed flow (651) back to the intermediate temperature storage space.

9. The facility of claim 8 wherein: the means for inducing a recirculating convection flow (600, 602) within the lower temperature storage space comprises: a first bank of storage columns; a second bank of storage columns; a first gap between the first and second banks; a first lateral gap between the first bank and a wall separating the lower temperature storage space from the intermediate temperature storage space; a second lateral gap between the second bank and a wall of the lower temperature storage space opposite the first lateral gap; and refrigerant coils (408) for cooling air in the first lateral gap and the second lateral gap.

10. The facility of claim 8 or 9 wherein: the directing of the mixed flow back to the intermediate temperature storage space comprises passing the mixed flow above the automation zone back toward the higher temperature storage space and then downward through the automation zone back into the intermediate temperature storage space and then, within the intermediate temperature storage space toward the lower temperature storage space and back up toward the automation zone as said flow (646) exiting the intermediate temperature storage space to, in turn, branch into a portion (648) passing within the automation zone over the lower temperature storage space and a portion (647) descending into the lower temperature storage space.

11. The facility of any one of the preceding claims further comprising: respective storage grid sections in the lower temperature storage space (40), the intermediate temperature storage space (42), and the higher temperature storage space (44); and rails in the automation zone spanning the storage spaces to allow the automated equipment to traverse the storage spaces.121577P524PC12. The facility of claim 11 wherein: the respective storage grid sections are configured to store bins and the automated equipment is configured to transport said bins.

13. The facility of claim 11 or 12 wherein: the respective storage grid sections are configured to store bins in a rectangular array of columns.

14. The facility of any one of the preceding claims wherein: the automated equipment is configured to drive on first and second orthogonal sets of tracks.

15. The facility of any one of the preceding claims wherein: the automated equipment is configured to reach down into the columns to retrieve or deposit an uppermost bin in a column.

16. The facility of any one of the preceding claims wherein the automated equipment comprises a plurality of bots, each bot having: a left pair of wheels and a right pair of wheels for moving in a first direction on first tracks; a front pair of wheels and an aft pair of wheels for moving in a second direction orthogonal to the first direction on second tracks; and a winch system for engaging a bin to raise and lower the bin.

17. The facility of claim 16 wherein each bot winch system has: a gripper plate suspended by four cables or straps and having latching members complementary to latching members of the bin.

18. The facility of any one of the preceding claims 12 wherein: respective lower temperature (140), intermediate temperature (142), and higher temperature (144) pick and replenishment areas are respectively associated with the lower temperature storage space, the intermediate temperature storage space, and the higher temperature storage space;121577P524PC the pick and replenishment areas have access to the associated storage space via an aperture in an associated wall of the storage space; the lower temperature pick and replenishment area and the intermediate temperature pick and replenishment area are respectively thermally isolated from each other and from a surrounding environment (30) within the facility; and the higher temperature pick and replenishment area is exposed to a surrounding environment (30) within the facility.

19. The facility of any one of the preceding claims further comprising: a pick and load area (160) having outbound transfer stations (167) with direct access to the intermediate temperature storage space.

20. The facility of claim 19 wherein: the transfer stations are in respective bays (160A-160C) and each bay is associated with a respective outbound loading dock (162).

21. The facility of claim 19 or 20 wherein: there are no outbound transfer stations with direct access to either the low temperature storage space or the high temperature storage space.

22. The facility of any one of the preceding claims wherein: the automated equipment comprises autonomous guided vehicles (AGV); and the automation zone contains charging stations for the AGV above the intermediate temperature storage space (42).

23. The facility of claim 22 wherein: a service mezzanine is aside the intermediate temperature storage space (42); and the charging stations comprise means for registering the AGV and means for electrically coupling to the AGV.

24. The facility of claim 22 or 23 wherein:33121577P524PC the charging stations for the AGV above the intermediate temperature storage space are at least 5 times greater in number than charging stations, if any, above the lower temperature storage space; and the charging stations for the AGV above the intermediate temperature storage space are at least 5 times greater in number than charging stations, if any, above the higher temperature storage space.

25. A method for operating the facility of any one of the preceding claims, the method comprising: maintaining the lower temperature storage space (40) at a first temperature; maintaining the intermediate temperature storage space (42) at a second temperature; maintaining the higher temperature storage space (44) at a third temperature; and maintaining a portion of the automation zone above the lower temperature storage space (40) at a fourth temperature above the first temperature.

26. The method of claim 25 further comprising: maintaining humidity control of a section (52) of the automation zone above the higher temperature storage space (44); and maintaining humidity control of a section (50) of the automation zone above the lower and intermediate temperature storage spaces (40, 42).

27. The method of claim 25 or 26 wherein: the maintaining the lower temperature storage space (40) at a first temperature comprises cooling opposite first and second portions of the lower temperature storage space to drive down passes (620, 621) of air, the down passes passing downward and then turning inward toward each other and then turning upward between first (520, 521) and second banks of storage columns.

28. The method of claim 27 wherein: said down passes pass within associated gaps (531, 532) adjacent associated walls of the lower temperature storage space; and34121577P524PC additional down passes pass within gaps (533, 534) transverse to said gaps and merge therewith to become one or more up passes (624, 625) between the banks.

29. The method of claim 27 or 28 wherein: the lower temperature storage space (40) is divided into separate spaces (40A, 40B, 40C) separated by walls (310); and each of the separate spaces have respective said first and second portions, down passes, and first and second banks.

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