Inventory management system in a warehouse

Abstract

A re-distribution system and method for consolidating case units in a logistics network are disclosed. The system comprises a grid framework structure (112) defining a plurality of storage columns in which storage containers are stacked, and a track system arranged above the storage columns. One or more load handling devices (36) are operable on the track system to retrieve and reposition storage containers within the grid framework structure. At least one pallet transfer station (86, 90) comprises a vision-assisted robotic arm (96a, 96b) configured to transfer case units between pallets and storage containers for storage in the grid framework structure, and to transfer case units from storage containers retrieved from the grid framework structure to one or more carriers in anticipation of a scheduled order. A control system is configured to sequence storage containers within the grid framework structure and to retrieve storage containers in accordance with forecasted demand. In certain configurations, a plurality of pallet transfer stations are arranged around the grid framework structure, each comprising a robotic arm equipped with a different type of end effector for handling case units of differing physical characteristics. The system enables active sorting and sequencing of case units within the grid framework structure and consolidation of mixed-SKU shipments with improved storage density and transport efficiency.

Description

[0001] Inventory Management System in a Warehouse

[0002] Field of the Invention

[0003] The present invention relates to logistics and warehouse automation systems, and more particularly to a re-distribution system for consolidating case units from pallets into carriers in anticipation of scheduled orders within a supply chain network serving one or more stores, fulfilment centres or other downstream recipients.

[0004] Introduction

[0005] In modem retail and e-commerce supply chains, goods are typically transported from suppliers or manufacturers in bulk form, grouped into case units and stacked on pallets. Each case unit generally contains goods of a single SKU type and may comprise a cardboard box, crate, tray, shrink-wrapped bundle or similar packaging format. Upon arrival at a warehouse or redistribution centre, the pallets are staged in an inbound area prior to further processing.

[0006] In distribution networks servicing multiple stores or fulfilment centres, it is frequently necessary to buffer and reorganise stock at a re-distribution centre before dispatching it to downstream locations. The re-distribution centre therefore functions as an intermediate hub that consolidates goods from multiple suppliers and prepares consolidated shipments based on forecasted demand at individual stores or fulfilment centres.

[0007] A significant technical challenge arises from the fact that case units arriving at a redistribution centre frequently have heterogeneous physical characteristics. Variations may include differences in dimensions, weight, rigidity, surface compliance, packaging geometry and stacking stability. Some case units may present flat upper surfaces suitable for suctionbased gripping, while others may comprise open crates requiring side-wall engagement by mechanical clamps. Furthermore, pallets may contain a mixture of different case unit types, particularly in grocery or mixed-merchandise supply chains.

[0008] Traditional automated de-palletising systems are typically designed around a single robotic arm equipped with a single type of end effector. Such systems may operate effectively for uniform case units but struggle to handle heterogeneous case units without manual intervention, tool changes or complex mechanical adaptation. These limitations reduce throughput and increase operational complexity.Conventional sorting systems frequently rely on networks of conveyors to sequence and distribute goods. Conveyor-based systems often require substantial floor space and mechanical infrastructure, which may be impractical in environments where land costs are high or where dense storage is desirable. Repeated retrieval and replacement of pallets in rack-based storage systems further increases handling time and risks product damage.

[0009] Automated storage and retrieval systems comprising grid framework structures and load handling devices have been widely adopted in fulfilment centres for dense storage and retrieval of goods. However, such systems have not traditionally been integrated with upstream pallet consolidation processes in a manner that addresses the challenges associated with heterogeneous case units.

[0010] There is therefore a need for a compact and integrated re-distribution system capable of buffering, sorting and consolidating case units having different physical characteristics, while reducing floor space requirements and improving storage density. There is further a need for such a system to be capable of routing pallets and carriers between different handling stations equipped with different end effector types so that heterogeneous case units can be processed reliably in an automated manner.

[0011] Summary of the Invention

[0012] The present invention provides a re-distribution system for consolidating a plurality of case units from a plurality of pallets into one or more carriers in anticipation of a scheduled order comprising a mixture of case units of different stock keeping unit (SKU) types. Each of the plurality of case units comprises a plurality of goods or items of a single SKU type.

[0013] In order to identify and track the different SKU types of goods entering the inbound area of a warehouse, a label is typically affixed to the packaging or to the case unit housing the goods. Such labels may include bar codes and / or radio frequency identification (RFID) tags. These identifiers enable an inventory management system to associate each case unit with a corresponding SKU type and to update inventory records continuously. For example, when goods are scanned at a point of sale register, inventory levels are adjusted to reflect deletion of one or more goods from stock. Similarly, when case units are received and scanned in the warehouse, the inventory management system updates stock levels to reflect replenishment.The distribution system utilises this SKU identification information to determine which case units are to be retrieved from the buffer and consolidated into carriers in anticipation of a scheduled order.

[0014] A principal aspect of the invention is the provision of a buffer configured not merely for passive storage but for active sorting and sequencing of case units prior to consolidation. The buffer comprises a grid framework structure including a plurality of storage columns for the storage of a plurality of storage containers in one or more stacks. A track system is arranged above the plurality of storage columns. The track system comprises a first set of parallel tracks extending in an X-direction and a second set of parallel tracks extending in a Y-direction transverse to the first set of parallel tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid cells. At least one port column extends downwardly from a grid cell through which one or more storage containers can be dropped off and / or picked up from the buffer.

[0015] One or more load handling devices are operable on the track system to retrieve one or more storage containers from the buffer and to move the storage containers within the grid framework structure. Each load handling device may comprise a driving assembly configured to move along the track system, a grabber device configured to releasably hold a storage container from above, and a lifting assembly configured to raise and lower the grabber device into and out of the grid framework structure via the grid cells.

[0016] Unlike conventional pallet racking systems in which case units remain statically stored on pallets without any inherent sequencing capability, the buffer of the present invention enables dynamic sorting and sequencing of case units within storage. The load handling devices are controlled by a control system to reposition storage containers within the grid framework structure in anticipation of a scheduled order. As a result, storage containers containing required case units may be sequenced and retrieved in an order corresponding to consolidation requirements.

[0017] The distribution system further comprises at least one pallet transfer station including at least one vision-assisted robotic arm positioned to interface with both pallets and storage containers. The control system comprises one or more processors and memory storing executable instructions which, when executed, cause the control system to control coordinated operation of the vision-assisted robotic arm and the load handling devices.To gather information from labels affixed to case units as goods enter the inbound area of the warehouse, the at least one vision-assisted robotic arm may optionally comprise a reader configured to read one or more labels provided on each of the plurality of case units. The labels may comprise bar codes, RFID tags, or other machine-readable identifiers containing data associated with the SKU type of the goods packaged in the case unit. The reader is configured to capture the label data during the de-palletising operation, and the captured data is communicated to the control system so that the SKU type of each case unit transferred into the buffer is recorded and associated with its corresponding storage container. This enables the control system to maintain accurate inventory records and to coordinate subsequent retrieval and consolidation of case units in anticipation of scheduled customer orders.

[0018] In particular, the pallet transfer station comprises a de-palletising station and a consolidation station, which may be implemented as separate stations or as functionally distinct regions of a common station. Alternatively, the de-palletising station and the consolidation station can be provided at a common pallet transfer station, the pallet transfer station being configurable to perform either de-palletising operations or consolidation operations. The de-palletising station is configured to receive one or more pallets arriving from the inbound staging area and to transfer one or more case units from the pallets into one or more storage containers for deposit into the buffer. Under control of the control system, a vision-assisted robotic arm positioned at the de-palletising station engages case units on the pallet and transfers the case units into storage containers positioned at the pallet transfer station, after which the storage containers are transported into the grid framework structure for storage.

[0019] The consolidation station functions as a picking station and is configured to receive one or more storage containers retrieved from the buffer in anticipation of a scheduled customer order and to transfer one or more case units from the retrieved storage containers into one or more carriers. The vision-assisted robotic arm at the consolidation station is operable, under control of the control system, to select required case units from the storage containers and to load the selected case units into the carrier so as to create a consolidated mixture of case units corresponding to the scheduled order.

[0020] Accordingly, one or more pallets carrying case units are transported from the inbound area to the pallet transfer station for de-palletisation into the buffer, and consolidated case units are subsequently assembled into one or more carriers at the consolidation station for outbounddistribution. In this manner, the pallet transfer station supports both inbound transfer of case units into the buffer and outbound consolidation of case units into carriers under coordinated control of the control system.

[0021] The control system is configured to instruct one or more load handling devices operable on the track system to retrieve selected storage containers from the buffer in accordance with the scheduled order and to deliver the retrieved storage containers to the pallet transfer station. Upon delivery, the vision-assisted robotic arm transfers the required case units from the retrieved storage containers to the carrier such that each carrier comprises a consolidated mixture of case units of different SKU types corresponding to the scheduled order.

[0022] Optionally , consolidation may alternatively be performed by loading the carrier with one or more storage containers comprising the required case units, rather than transferring individual case units from the storage containers. In such examples , the control system instructs the load handling devices to retrieve complete storage containers containing the selected case units and to deliver the storage containers to the pallet transfer station. The pallet transfer station is then configured to load the storage containers directly into the carrier in anticipation of the scheduled customer order.

[0023] In some implementations, the at least one vision-assisted robotic arm comprises a first vision-assisted robotic arm configured to transfer case units from pallets to storage containers and a second vision-assisted robotic arm configured to transfer one or more case units from the storage containers and / or storage containers comprising one or more case units from the buffer to carriers. Where the second vision-assisted robotic arm is configured to transfer storage containers, the robotic arm may be equipped with an end effector having engagement features corresponding to those of the grabber device of the load handling device. In particular, the end effector of the vision-assisted robotic arm may be configured to releasably engage one or more complementary engagement portions formed on the storage container, in a manner analogous to the grabber device used by the load handling device within the grid framework structure.

[0024] By providing the vision-assisted robotic arm at the pallet transfer station with containerengaging features compatible with the storage containers, complete storage containers retrieved from the buffer can be gripped, lifted and positioned directly into the carrier without intermediate transfer of the case units. This enables flexibility in consolidation strategy,allowing the system to select between case-unit-level transfer and container-level transfer depending on the scheduled order, container configuration, and operational requirements.

[0025] In alternative examples, the pallet transfer station comprises a plurality of vision-assisted robotic arms, each of the plurality of vision-assisted robotic arms comprising a different type of end effector configured to handle a different type of case unit. The plurality of end effectors may include suction-based end effectors and mechanical grippers. In some examples , a first type vision-assisted robotic arm comprises a suction cup end effector and a second type vision-assisted robotic arm comprises a mechanical gripper end effector.

[0026] By providing a plurality of vision-assisted robotic arms equipped with different end effector types, the pallet transfer station is capable of reliably handling case units having different physical characteristics within the same consolidation operation. This enables case units of differing sizes, shapes and packaging formats to be combined within a single storage container or carrier in a controlled manner.

[0027] Equally, the re-distribution system may further comprise a plurality of different types of end effectors configured to handle different types of case units having differing physical characteristics. Each of the plurality of end effectors is configured to interface with the at least one vision-assisted robotic arm, for example via a releasable mounting interface enabling selective coupling of a chosen end effector to the robotic arm. The control system is configured to select an appropriate end effector type based on characteristics of the case units being handled and to control the robotic arm accordingly. In particular, the control system is configured to select different types of end effectors to (a) transfer different types of case units between one or more pallets and one or more storage containers during de-palletisation, and (b) transfer different types of case units between one or more storage containers retrieved from the buffer and one or more carriers during consolidation, such that each of the one or more carriers comprises a consolidated mixture of case units of different SKU types.

[0028] As a result, the system can select and arrange heterogeneous case units so as to maximise utilisation of available storage space or carrier volume. In particular, case units that are best handled by suction may be positioned in locations that optimise planar contact and stacking, while case units requiring mechanical gripping may be positioned in complementary spaces, thereby enabling more complete filling of both the horizontal footprint and vertical height of the storage container or carrier. This flexibility in handling different case unit types supportsimproved packing density and contributes to achieving substantially full cube utilisation of the carrier or storage volume.

[0029] In further examples, the system comprises a plurality of pallet transfer stations arranged at different locations around the grid framework structure. Each pallet transfer station comprises at least one vision-assisted robotic arm, and the vision-assisted robotic arm of each pallet transfer station comprises an end effector of a different type from the robotic arms at the other pallet transfer stations. The control system is configured to control one or more automated pallet movers to move one or more pallets and / or carriers between the plurality of pallet transfer stations such that different case unit types are processed by compatible end effector types.

[0030] The grid framework structure may comprise a plurality of port columns, each port column being associated with a respective pallet transfer station. A conveyor system may be configured to transport storage containers between the at least one port column and the pallet transfer station for accessing the contents of the storage container external of the grid framework structure.

[0031] The pallet transfer station may further comprise a lifting mechanism configured to cooperate with a storage container so as to move one or more case units vertically relative to a bottom wall of the storage container. The lifting mechanism may comprise a push rod arranged to extend through an opening formed in the bottom wall of the storage container and a drive mechanism configured to move the push rod in a vertical direction within the internal volume of the storage container. By extending the push rod upwardly, one or more case units supported within the storage container can be raised relative to the bottom wall and, where required, above an upper rim of the storage container. This arrangement increases the accessibility of the case units to the vision-assisted robotic arm positioned at the pallet transfer station, since the robotic arm is not required to reach downwardly into the storage container to engage the case units.

[0032] Optionally, the lifting mechanism is configured to cooperate directly with the conveyor system associated with the pallet transfer station. The lifting mechanism may be integrated into or positioned beneath a section of the conveyor system such that a storage container transported on the conveyor passes over the lifting mechanism. When the storage container is positioned above the lifting mechanism, the push rod may extend upwardly through the opening in the bottom wall of the storage container to raise one or more case units upwardly relative to the bottom wall and above the rim of the storage container. This configuration allows the liftingmechanism to treat storage containers while they are supported on the conveyor system, both during loading of case units into the storage container and during retrieval of case units from the storage container. As a result, vertical repositioning of case units can be performed in-line with conveyor movement, thereby simplifying station layout and improving operational efficiency.

[0033] Optionally, one or more storage containers comprise a base plate positioned within the storage container and configured to support one or more case units. The base plate is arranged to cooperate with the push rod such that operation of the drive mechanism causes corresponding vertical movement of the base plate relative to the bottom wall of the storage container. In use, the base plate may be raised to a presentation position in which the supported case units are positioned at or above the upper rim of the storage container, thereby presenting the case units to the vision-assisted robotic arm in an accessible manner. As a result, the robotic arm can engage, lift or laterally transfer the case units without inserting the end effector into the interior of the storage container, which improves reliability of engagement, reduces collision risk with container walls, and facilitates handling of case units having different physical characteristics.

[0034] The pallet transfer station may additionally comprise a pallet lifting device including a pallet support configured to receive and support a pallet and a lifting drive mechanism configured to move the pallet support in a vertical direction. The control system is operable to control the lifting drive mechanism so as to incrementally raise or lower the pallet, thereby presenting successive layers of case units to the vision-assisted robotic arm at a substantially consistent working height.

[0035] Optionally, movement of the pallet in the vertical direction is indexed in sequential steps, each sequential step corresponding substantially to the height of a layer of case units on the pallet. By indexing the pallet upwardly or downwardly layer by layer, the uppermost layer of case units is maintained within a defined working envelope of the vision-assisted robotic arm. This reduces the requirement for large vertical articulation of the robotic arm and enables transfer of one or more case units between the pallet and one or more storage containers with limited vertical movement of the arm.

[0036] By reducing the range and complexity of movement required of the vision-assisted robotic arm, the pallet lifting device allows the use of more simplified and lower-cost robotic architectures. For example, a robotised arm providing movement primarily in the X and Y directions, suchas a three-axis robotised arm or a SCARA (Selective Compliance Articulated Robot Arm), may be used to transfer one or more case units between the pallet and the storage containers. In such arrangements, the vertical positioning required for accessing successive layers of case units is provided by the pallet lifting device rather than by vertical extension of the robotic arm itself. This improves positional accuracy, reduces cycle time, enhances reliability when handling case units of varying sizes and physical characteristics, and lowers overall system cost.

[0037] At least one of the one or more carriers may comprise a pallet. Optionally , at least one of the one or more carriers comprises a stackable stillage comprising a base frame, at least four comer members extending upwardly from the comers of the base frame to define a storage space or volume, a support for receiving a plurality of case units thereon, the support being moveable relative to the base frame in a vertical direction within the storage space or volume, and a lifting mechanism configured to move the support relative to the base frame. The comer members may include bracing members and / or side panels defining confinement within the storage space.

[0038] In certain examples, the distribution system further comprises an inventory handling station operable in cooperation with the grid framework structure. The inventory handling station is configured to interface with the grid framework structure via at least one port column such that a load handling device operating on the track system can drop off and / or pick up storage containers to and from the inventory handling station. In this manner, storage containers retrieved from the buffer may be delivered to the inventory handling station for processing and subsequently returned to the grid framework structure for storage.

[0039] The inventory handling station may be configured to move goods between storage containers within the buffer. One or more of the plurality of case units comprise goods or items, and in certain circumstances it is advantageous to move individual goods rather than entire case units between storage containers. The inventory handling station may therefore facilitate selective removal of one or more goods from a first storage container and transfer of the removed goods into a second storage container. By enabling goods-level transfer in addition to case-unit-level transfer, the system provides increased flexibility in preparing storage containers with desired mixtures of SKU types or quantities in anticipation of scheduled orders.

[0040] The inventory handling station may be implemented manually or may comprise an automated system, such as an on-grid robotic pick station mounted on the track system above the gridframework structure. In the case of an on-grid robotic pick station, a vision-assisted robotic arm is operable to access storage containers positioned within grid cells and to transfer one or more goods from a first storage container to a second storage container under the control of the control system.

[0041] By enabling movement of individual goods between storage containers, the system allows storage containers to be prepared so as to comprise a mixture of SKU types or specific quantities of goods that may not be achievable by transferring complete case units alone. For example, where a case unit comprises a tray containing multiple goods that are readily accessible from above, one or more goods may be removed from the tray while the tray remains within the storage container, and transferred to another storage container without removing the entire case unit from its original storage container. For example, the on-grid robotic pick station is configured to remove one or more goods from a first tray or crate or storage container and transfer the goods to a second tray or crate while both trays or crates remain in situ within their respective storage containers stored in the grid framework structure. This capability allows fine-grained preparation of storage containers in anticipation of a scheduled order, reduces the number of storage containers required to be retrieved for consolidation, and further improves utilisation of storage container volume and overall storage density within the buffer.

[0042] In a further aspect, the invention provides a system comprising a distribution centre incorporating the re-distribution system described above, at least one fulfilment centre, and an inventory management system. The inventory management system comprises a stock database storing data indicative of the quantity of stock comprising a plurality of SKU types at the redistribution centre and at the at least one fulfilment centre. A control unit in communication with the stock database is configured to provide instructions to the control system of the redistribution system to replenish stock at the at least one fulfilment centre in response to a stock level of the one or more SKU types at the at least one fulfilment centre being below a predetermined number of case units. The scheduled order may comprise data associated with forecasted consumption of the plurality of SKU types over a predetermined period of time. Optionally, the at least one fulfilment centre comprises a plurality of fulfilment centres, each of the plurality of fulfilment centres being configured to fulfil one or more customer orders comprising one or more SKU types.

[0043] In the case where the carrier comprises a pallet, consolidation of case units onto a pallet is performed so as to maximise utilisation of the available pallet volume. A plurality of case unitsis transferred to the pallet such that multiple layers of case units are built up on the pallet. The case units are arranged to maximise both horizontal and vertical utilisation of the pallet footprint and height, thereby substantially eliminating unused volume and aiming for full “cube utilisation”. In practical terms, consolidation is controlled such that the pallet density, defined as the total mass of case units loaded onto the pallet divided by the volume occupied by the pallet, is equal to or greater than a predetermined threshold, for example equal to or greater than 0.1 tonnes per cubic metre and preferably equal to or greater than 0.3 tonnes per cubic metre.

[0044] To achieve such pallet density and maximise utilisation of pallet space, the plurality of case units retrieved from the grid framework structure for consolidation onto a pallet is preferably above a predetermined number of case units. The predetermined number is calculated so as to ensure adequate filling of the pallet in both horizontal and vertical directions. When the number of case units required by a particular fulfilment centre exceeds the predetermined threshold, the control unit instructs one or more load handling devices to retrieve multiple storage containers containing the relevant case units from the grid framework structure for consolidation. This ensures that sufficient case units are available to build multiple layers on the pallet and achieve the desired pallet density.

[0045] Conversely, where the number of case units required is below the predetermined threshold, there may be insufficient case units to adequately fill a pallet to the target pallet density for efficient transport. In such circumstances, the inventory management system may defer replenishment until additional case units are available, or may consolidate case units from multiple scheduled orders, thereby ensuring that outbound pallets are loaded with a consolidated mixture of case units that achieves efficient utilisation of pallet space and transport capacity.

[0046] In a further aspect, a method is provided for distributing stock comprising a plurality of case units to one or more fulfilment centres. The method comprises receiving, at an inventory management system, a request for a scheduled order of case units; instructing a re-distribution system to retrieve case units from the buffer; and consolidating the case units into one or more carriers such that each carrier comprises a consolidated mixture of case units of different SKU types. The method may further comprise instructing vision-assisted robotic arms to transfer case units between pallet transfer stations and storage containers and instructing load handling devices to deposit and retrieve storage containers within the grid framework structure.The present invention therefore provides an integrated re-distribution architecture in which a grid-based buffer actively sorts and sequences case units in storage, and in which heterogeneous case units are selectively handled by compatible end effectors and consolidated into carriers in anticipation of scheduled customer demand.Brief Description of the Drawings

[0047] Further features and aspects of the present invention will be apparent from the following detailed description of an illustrative example made with reference to the drawings, in which:

[0048] Figure 1 is a schematic illustration showing the work flow of stock between a distribution centre and a plurality of fulfilment centres (CFC) in a distribution network according to the present disclosure;

[0049] Figure 2 is a block diagram showing an inventory management system for managing the distribution of stock to the plurality of fulfilment centres.

[0050] Figure 3 is a schematic illustration of a storage and retrieval system comprising a grid framework structure according to the present disclosure.

[0051] Figure 4 is a schematic perspective view of the load handling device showing the lifting device gripping a container from above.

[0052] Figure 5(A and A) are schematic perspective cut away views of the load handling device of Figure 4 showing (A) a container accommodated within the container receiving space of the load handling device and (B) the container receiving space of the load handling device.

[0053] Figures 6(A and B) shows the distribution processes in a supply chain of a retail store operating in the E-commerce market; where (A) illustrates the logistical processes from supplier or manufacturer to CFC; and (B) illustrates the logistical processes from supplier or manufacturer to fulfilment centre (CFC) or retail store via a distribution centre.

[0054] Figure 7(A and B) illustrates the logistical processes of (A) the distribution centre; and (B) fulfilment centre (CFC) shown in Figures 6(A and B).

[0055] Figure 8 illustrates the logistical processes where a single storage and retrieval system in the form of the grid framework structure is used to sort case units for distribution to the CFC and for sorting the goods for fulfilling one or more end customers.

[0056] Figure 9 is a schematic illustration of a re-distribution system according to the present disclosure.

[0057] Figure 10 is a schematic illustration of a top plan view of the re-distribution system shown in Figure 9.Figure 11 is a schematic perspective view of a series of pallet transfer stations, each of the series of pallet transfer stations comprising a de-palletising station that interface with the grid framework structure to transfer case units between the pallet transfer stations and the grid framework structure.

[0058] Figure 12 is a schematic perspective view of a series of pallet transfer station, each of the series of pallet transfer stations comprising a consolidation station that interface with the grid framework structure to transfer case units between the pallet transfer station and the grid framework structure.

[0059] Figure 13 A and Figure 13B are perspective views of a first type of end effector used to handle a type of case unit, where (A) show the end effector in absence of the case unit, and (B) shown the end effector carrying a case unit.

[0060] Figure 14 is a perspective view showing an end effector comprising a plurality a suction cup and a pair of clamps to secure the case unit to the end effector.

[0061] Figure 15 is a perspective view showing an end effector comprising a plurality of suction cups in absence of the pair of clamps to increase the ability to handle different size / shape of case units.

[0062] Figure 16 is a perspective view of an end effector based purely on mechanical grippers or clamps for handling the case units.

[0063] Figure 17 is a perspective view showing the interface between the robotic arm and a plurality of different types of the end effectors of Figures 13(A and B) to 16.

[0064] Figure 18A and Figure 18B are perspective views showing the different types of case units that can be accommodated by the storage containers, where (A) show a box type case unit, and (B) show the case unit in the form of a crate.

[0065] Figure 19A and Figure 19B is a perspective view of a lifting mechanism comprising a plurality of push rod that cooperate with the base of the storage container, where (A) show the base of the storage container comprising a plurality of holes for receiving a plurality of push rods; and (B) showing the interaction of the plurality of push rods extending through the plurality ofholes in the base of the storage container to lift one or more case unit above the rim of the storage container.

[0066] Figure 20 is a perspective view of an autonomous transport vehicle used to transport the carrier between different pallet transfer station.

[0067] Figure 21 is a schematic illustration of a stillage according to the present disclosure to transport consolidated case units to the fulfilment centres.

[0068] Figure 22 is a schematic illustration of the stacking of the stillages according to the present disclosure.

[0069] Figure 23 is a schematic illustration showing a vision assisted robotized arm being configured to consolidate the case units into the stillage of the present disclosure.

[0070] Figure 24 is a schematic illustration of the arrangement of the case units of a layer of a pallet or carrier, where (a) is a spiral arrangement of the case units; and (b) is an overlapping brick’ pattern of the case units.

[0071] Figure 25 is a flowchart of the process to de-palletise a pallet of case units for storage in the grid framework structure.

[0072] Figure 26 is a flowchart of the process to consolidate a plurality of case units retrieved from the grid framework structure into the carrier.

[0073] Detailed Description

[0074] Reference is made to the accompanying drawings in which like reference signs denote like features throughout the specification. The following description sets out detailed examples of a re-distribution system configured to receive palletised case units, buffer and sequence those case units within a grid framework structure, and consolidate selected case units into carriers in anticipation of scheduled downstream demand.

[0075] In conventional redistribution warehouses, palletised case units are received from suppliers and temporarily stored in rack-based storage systems within a staging area. Where goods are fragile, particularly grocery items, pallets are not stacked vertically in order to prevent compression damage to case units positioned on lower pallets. When a downstream fulfilmentcentre requires replenishment of a particular SKU, a pallet containing that SKU is manually retrieved from the rack system, typically by forklift truck, lowered to ground level, partially unloaded, and then returned to storage. This repeated removal and re-placement of pallets increases labour time and significantly increases the probability of packaging damage, product spillage, and stock inaccuracy.

[0076] Furthermore, rack-based storage systems do not inherently provide sorting or sequencing functionality. Case units remain grouped in the configuration in which they arrived from the supplier. When mixed-SKU consolidation is required for dispatch to a fulfilment centre, repeated pallet retrieval operations are required. Conveyor-based sortation networks have been used in some redistribution environments; however, such systems require substantial floor space and complex mechanical infrastructure. In regions where land cost is high, storage density per square metre is a critical design parameter. It is therefore desirable to minimise the footprint required for sorting and sequencing operations while maintaining high throughput and reliability.

[0077] Figure 1 illustrates a distribution network (2) comprising a re-distribution centre (4) and a plurality of customer fulfilment centres, CFC, (6). The re-distribution centre (4) receives goods (8) from multiple suppliers or manufacturers via delivery vehicles (10). Each supplier typically delivers goods of a single SKU type or attribute, grouped into case units (92) and stacked on pallets. The re-distribution centre (4) acts as an intermediate consolidation hub positioned upstream of the customer fulfilment centres (6). Rather than shipping directly from supplier to fulfilment centre, goods are first buffered and reorganised at the re-distribution centre (4) in anticipation of forecasted downstream demand.

[0078] The case units (92) may comprise cardboard boxes, crates, trays, shrink-wrapped bundles or other packaging formats (see Figure 18A and 18B). Each case unit typically contains goods of a single SKU type. Depending on forecast demand at individual customer fulfilment centres (6), the number of case units stacked on a pallet may vary from supplier to supplier. Pallets are transported from delivery vehicles (10) into a staging area (84) within the warehouse (see Figure 7 A).

[0079] As illustrated in Figure 2, the re-distribution centre (4) operates in coordination with an inventory management system (12). The inventory management system comprises a control system (14), a main database (16), and local databases (18, 20, 22) associated with respective customer fulfilment centres (6). The control system (14) comprises one or more processors andmemory configured to execute stock management algorithms. The memory may include RAM, ROM, EEPROM, flash memory, database storage, and other suitable memory forms. The processor may comprise a general purpose processor, FPGA, ASIC, DSP, or equivalent computational device.

[0080] The control system (14) maintains real-time data regarding SKU quantities stored within the re-distribution centre (4) and within each fulfilment centre (6). When case units are received in the staging area (84), machine-readable labels such as barcodes or RFID tags are scanned. The SKU information is recorded in the main database (16) and associated with specific storage containers once inducted into the buffer. When an order of case units is instructed to be delivered to the customer fulfilment centre (CFC) for fulfilling one or more customer orders, the case units are typically loaded onto pallets and transported to the CFC where they are held in storage (26, 28, 30) until they are ready to be dispatch to customers serviced by the customer fulfilment centres. Storage in the customer fulfilment centres can be a ‘cubic’ grid framework structure discussed further below or a rack-based storage system.

[0081] Forecasting algorithms within the control system calculate required replenishment quantities for each customer fulfilment centre (6) based on historical consumption patterns, seasonal variations, promotional activity (for example buy-one-get-one-free promotions), safety stock levels, and demand fluctuations.

[0082] When the stock level of one or more SKU types at a fulfilment centre (6) falls below a predetermined threshold, the control system generates a scheduled order instructing retrieval of case units from the re-distribution centre (4). The scheduled order specifies required SKU types and quantities to replenish the fulfilment centre to its forecasted safety level.

[0083] The re-distribution centre (4) incorporates a buffer (24), shown schematically in Figure 3, which comprises a grid framework structure (31). The grid framework structure (31) defines a three-dimensional storage architecture capable of storing storage containers (34) in stacked arrangements within storage columns (42). The grid framework structure comprises upright members (44) supporting horizontal members (48, 50) arranged in a grid pattern to form grid cells. A track system (46) is supported above the storage columns and comprises rails or tracks (52) extending in orthogonal X and Y directions.

[0084] Load handling devices (36) operate on the track system (46). As illustrated in Figures 4 and 5, each load handling device comprises a vehicle body (60) supported by a first set of wheels (62) and a second set of wheels (64). The first set of wheels engages a first set of rails or tracks toenable movement in a first direction (X-direction), and the second set of wheels engages a second set of rails or tracks to enable movement in a second direction (Y-direction). One or both sets of wheels may be vertically actuated to disengage from respective rails, enabling directional change.

[0085] Each load handling device (36) comprises a lifting assembly including tethers (66) and a grabber device (68). The grabber device (68) includes gripper elements configured to engage complementary recesses or apertures in the rim of a storage container (34). The gripper elements are movable between a contracted position and an expanded position to secure the storage container. The grabber device lifts the storage container into a container receiving recess (70) formed in the lower portion of the vehicle body (60). In this configuration, the storage container is lifted clear of the rails, allowing the load handling device to transport the container laterally across the grid framework structure.

[0086] The grid framework structure (31) thus enables dynamic repositioning of storage containers under control of the control system (14). Unlike rack-based storage, storage containers are not statically located; rather, they are actively sorted and sequenced within the buffer (24). The control system may instruct load handling devices (36) to reposition storage containers in anticipation of scheduled orders so that containers containing required case units are located at accessible depths and in retrievable sequence.

[0087] Figure 6 illustrates supply chain alternatives. In supply chain (72) shown in Figure 6(A), goods are delivered directly from supplier (74) to fulfilment centre (76). This can result in congestion in the inbound area of the fulfilment centre. In contrast, supply chain (73) shown in Figure 6(B) includes the re-distribution centre (80) upstream of the fulfilment centre (76). Goods are first buffered and sequenced at the re-distribution centre (80), and only the forecasted required quantities are dispatched to the fulfilment centre (76). This reduces inbound congestion and enables smaller fulfilment centres with lower on-site stock levels.

[0088] In contrast to using a network of conveyors to sort and sequence case units for distribution to one or more CFCs, the present disclosure utilizes a storage and retrieval system comprising a grid framework structure discussed above. Thus, the retail supply chain's distribution processes shown in Figure 6(B), from manufacturer to end customer, incorporate multiple automatic storage and retrieval systems. Each of the storage and retrieval systems uses a grid framework structure to store and retrieve goods for dispatch to different types of customers within the supply chain.For example, the logistical processes in the supply chain (73) comprises a first storage and retrieval system for the sorting and sequencing of case units in the re-distribution centre (80) (defining a first distribution process) and a second storage and retrieval system in a CFC (76) (defining a second distribution process) for storage and retrieval of the goods or eaches for dispatch to one or more end customers (78).

[0089] However, the distribution centre (80) according to the present disclosure is not limited to distributing case units to customer fulfilment centres (76). In alternative arrangements, the distribution centre (80) can, optionally, be configured to distribute case units to other recipients, including retail stores or directly to end customers. As illustrated by an additional distribution path in Figure 6(B), case units that have been sorted and consolidated at the distribution centre (80) into one or more carriers may be transported directly to a retail store (77) for sale to end customers.

[0090] Figure 7(A) illustrates the logistical processes at the re-distribution centre (80), including staging area (84), de-palletising station (86), buffer (88), and consolidation station (90). Figure 7(B) illustrates the downstream fulfilment process, including de-trash station (108), decant station (110), grid framework structure (112), and pick station (114).

[0091] At the re-distribution centre (80), pallets (84) arriving from suppliers are de-shrouded to remove straps and shrink wrap. Pallets are then transported to pallet transfer stations (94), illustrated in Figures 9 and 10. Each pallet transfer station may include a de-palletising station (86) and a consolidation station (90). The de-palletising station (86) includes a de-palletising device (96a) configured to remove case units (92) from pallets and transfer them into storage containers (34) positioned on a conveyor system (100a). In the particular example shown in Figure 7(A), the de-palletising device (96a) comprises a vision assisted robotic arm.

[0092] The vision-assisted robotic arm (96a) includes image acquisition sensors configured to capture images of the upper layer of case units on the pallet. Image data is transmitted to the control system (14), which determines the position and orientation of each case unit. The robotic arm comprises articulated segments connected by pivot joints allowing roll and pitch rotation. An end effector (98, 198, 298, 398) mounted at the distal end of the robotic arm engages case units for transfer.

[0093] Storage containers (34) filled with case units are transported via a first conveyor system (100a) to a pick-up port column or first port column (102a). Load handling devices (36) retrieve the containers through the port column and store them within the grid framework structure (31).The grid framework structure includes at least one pick-up port column or first port column (102a) and at least one drop-off port column or second port column (102b), as illustrated in Figure 10, which is not used for storing storage containers, but which comprises a location where the robotic load handling devices can drop off and / or pick up storage containers so that they can be transported to a location where the storage containers can be accessed from outside of the grid framework structure or transferred out of or into the grid framework structure. 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 “port column”.

[0094] The drop-off port column (102b) is used to deliver retrieved storage containers to the consolidation station (90) via second conveyor system (100b). The first port column or pickup port column (or inlet port column) (102a) may, for example, comprise a dedicated pick-up or inlet port where the load handling device operable on the grid framework structure (31) can pick up one or more storage containers that have been transported upwardly through the first port column from the pick-up port at the pallet transfer station and the second port column or drop-off port column (or outlet port column) (102b) comprises a dedicated drop-off or outlet port where the load handling device operable on the grid framework structure can drop off one or more storage containers to the drop-off port to be transported to the pallet transfer station (see Figure 10).

[0095] As shown in Figure 10, the first conveyor system (100a) extends from the de-palletizing station (86) into the first port column (102a) and the second conveyor system (100b) extends from the second port column (102b) to the consolidation station (90). One or more loaded storage containers comprising one or more case units at the de-palletising station (86) is transported to the pick-up port via the first conveyor (100a) and is subsequently picked up by a load handling device (36) operable on the grid framework structure (31) through the pick-up column (102a) for storage in the grid framework structure (31).

[0096] In contrast to the de-palletising station (86), to consolidate a plurality of case units for distribution to one or more CFCs in the distribution network, one or more load handling devices (36) operable on the grid framework structure is instructed to retrieve one or more target storage containers in storage, each of the one or more target storage containers comprising one or more case units required to fulfil the scheduled order at a CFC. The load handling device transports the one or more target storage containers from their storage location to the drop-off port via the drop-off port column (102b). The storage containers are then transported to the consolidationstation (90) via the second conveyor system (100b). At the consolidation station (90), a repalletising device (96b) is instructed to pick up the plurality of case units from the one or more of the retrieved storage containers on the second conveyor (100b) and transfer the plurality of case units to a fresh pallet or carrier used to transport the plurality of case units to the CFC (76). Like the de-palletising device (96a), the re-palletising device (96b) can comprise a vision assisted robotic arm. The re-palletising or palletising device (96b) can be the same depalletising device used to de-palletise the pallets at the de-palletizing station (86) or a separate palletising device. For example, a single vision-assisted robotic arm may be provided at the pallet transfer station (94) and configured to operate selectively in a de-palletising mode or a consolidation mode. In the de-palletising mode, the vision assisted robotic arm transfers case units from a pallet to one or more storage containers for induction into the buffer, and in the consolidation mode the same robotic arm transfers case units from one or more storage containers retrieved from the buffer to a carrier.

[0097] The conveyor system (100a, 100b) is not limited to the specific configuration illustrated in Figure 10 and may be implemented in a variety of alternative arrangements depending on layout constraints and throughput requirements. In one example, the first conveyor system (100a) associated with the de-palletisation station (86) may be arranged to cooperate with two port columns of the grid framework structure (31). A first port column may function as a dropoff port column through which empty storage containers (34) are delivered from the grid framework structure (31) to the de-palletisation station (86). A second port column may function as a pick-up port column through which storage containers (34) loaded with one or more case units are transferred from the de-palletisation station (86) back into the grid framework structure (31). In certain examples, the first conveyor system (100a) may have a generally ‘U’-shaped configuration such that opposing ends of the conveyor interact respectively with the first and second port columns. This arrangement enables storage containers to be received from the grid, conveyed past the de-palletisation station for loading, and subsequently returned to the grid via a separate port column in a continuous loop.

[0098] Similarly, the second conveyor system (100b) associated with the consolidation station (90) may be configured to interact with two port columns. A first port column may serve as a dropoff port column through which storage containers (340 loaded with one or more case units are delivered from the grid framework structure (31) to the consolidation station (90). A second port column may serve as a pick-up port column through which storage containers (34), once emptied or partially emptied at the consolidation station (90), are returned to the gridframework structure (31) for storage. The second conveyor system (100b) may likewise have a generally ‘U’-shaped configuration, enabling storage containers to travel from a first port column to the consolidation station and then to a second port column for return to the grid. Accordingly, each conveyor system (100a, 100b) may support bidirectional and looped transfer of storage containers (34) between the pallet transfer stations and the grid framework structure (31), and the number, positioning, and geometry of port columns and conveyor segments may be selected to optimise operational efficiency and throughput.

[0099] The pallet transfer station may further include a pallet lifting device to raise and / or lower pallets incrementally as successive layers of case units are either removed or added. This maintains consistent presentation height for the robotic arm and reduces the required articulation range. As illustrated in Figure 11, the re-distribution centre may comprise a plurality of pallet transfer stations (94) arranged around the periphery of the grid framework structure (31). Each pallet transfer station (94) interfaces with the grid framework structure (31) via one or more associated port columns (102a, 102b) and corresponding conveyor systems (100a, 100b). The plurality of pallet transfer stations enables parallel handling of case units (92) having different physical characteristics and supports both inbound de-palletisation and outbound consolidation operations.

[0100] As further illustrated in Figure 12, a plurality of consolidation stations (90) are positioned at different locations around the periphery of the grid framework structure (31). Each consolidation station (90) is configured to receive one or more storage containers (34) retrieved from the buffer (88) and to consolidate case units (92) into one or more carriers (95). The grid framework structure (31) is configured to supply storage containers (34) to each consolidation station (90) via at least one associated port column (102), such that one or more load handling devices (36) operating on the track system (46) deposit selected storage containers into the associated port column for transfer to the respective consolidation station. A corresponding conveyor system (100c, lOOd) transports the storage containers between the port column and the consolidation station. This arrangement enables multiple consolidation stations (90) to operate in parallel, thereby increasing consolidation throughput in anticipation of scheduled orders.

[0101] In one arrangement, each pallet transfer station (94) comprises at least one vision-assisted robotic arm (96a) permanently equipped with a specific type of end effector. The end effector at each pallet transfer station differs from that at the other pallet transfer stations. In thismanner, heterogeneous case units (92) can be directed, under control of the control system (14), to pallet transfer stations equipped with compatible handling mechanisms.

[0102] The pallet transfer stations (94) may be distributed spatially along different sides of the grid framework structure (31), as shown in Figure 11. Each pallet transfer station includes a depalletising station (86) and may additionally include a consolidation station (90). In some examples, the de-palletising station (86) and the consolidation station (90) are implemented at separate pallet transfer stations. In other examples, a single pallet transfer station (94) is configurable to operate selectively in a de-palletising mode or a consolidation mode, such that the same physical station may alternately perform inbound case-unit transfer into storage containers (34) and outbound consolidation into carriers (95).

[0103] Where a plurality of pallet transfer stations (94) are provided, each station may be dedicated to handling case units having specific physical characteristics, such as differences in size, weight, rigidity, packaging geometry, or surface compliance. For example, some case units may present flat upper surfaces suitable for suction-based engagement, while others may comprise open crates or trays requiring side-wall engagement by mechanical clamps.

[0104] The control system (14) is configured to determine, based on SKU data and / or image analysis, which end effector type is appropriate for handling a particular case unit. When a pallet (84) comprising a single case unit type arrives at the staging area (84) and is transported to a pallet transfer station, the control system identifies the case unit type and routes the pallet to the pallet transfer station equipped with the corresponding end effector.

[0105] In the case where a pallet comprises a mixture of different case unit types, the control system may generate a sequence of pallet transfer stations (94). An autonomous pallet mover or transport vehicle is then instructed to transport the pallet sequentially between different pallet transfer stations, each pallet transfer station de-palletising those case units compatible with its end effector type. This sequential routing enables a mixed pallet to be fully de-palletised into storage containers (34) without manual intervention or physical reconfiguration of robotic tooling.

[0106] Figures 13A and 13B illustrate a first type of end effector (98) suitable for mechanically clamping a case unit. The end effector (98) comprises a mounting portion (126) configured to couple to the distal end of the robotic arm (96a), a lower support member (128), and an upper support member (130). The lower support member (128) is configured to engage a lower wall of the case unit, and the upper support member (130) is configured to engage an upper wall ofthe case unit. A vertical actuation mechanism moves the upper support member relative to the lower support member between a released position and a clamping position. In the clamping position, the upper and lower support members apply opposing forces to clamp the case unit therebetween.

[0107] As shown in Figure 13B, a plurality of suction cups or suction pads (132) may be mounted to a rear portion of the lower support member (128) to provide additional securing force by engaging a side surface of the case unit. This combination of clamping and suction enhances retention stability during lifting and transport.

[0108] Figure 14 illustrates a second type of end effector (198) comprising a mounting portion (126), a support structure (134), and a plurality of suction cups or suction pads (136) arranged in an array. The suction cups are fluidly connected to a vacuum supply and generate holding force when engaged against a surface of a case unit. Each suction cup may be mounted via a compliant coupling (138), allowing relative movement to accommodate variations in surface height and geometry. Downwardly extending walls (140) may partially surround the suction cups to provide additional lateral guidance and structural reinforcement.

[0109] Figure 15 illustrates a further suction-based end effector (298) comprising a support plate (142) to which suction assemblies (136) are mounted. Each suction assembly includes a compliant mounting mechanism enabling the suction cup to adjust relative to the support plate while maintaining vacuum engagement. This configuration is particularly suitable for case units having flat upper surfaces but minor surface irregularities.

[0110] Figure 16 illustrates a purely mechanical end effector (398) comprising a first pair of clamps (144) and a second pair of clamps (146). The first pair of clamps engage opposing side surfaces of a case unit, while the second pair engage opposing side surfaces transverse to the first pair. At least one actuation mechanism moves the clamps between open and clamping positions. When in the clamping position, the clamps apply inwardly directed forces to mechanically restrain the case unit. This end effector configuration is particularly suited to crates or trays that do not provide suitable upper surfaces for suction engagement.

[0111] Figure 17 illustrates an interface arrangement between the robotic arm and a plurality of end effector types. The mounting portion (126) of each end effector is configured to detachably couple with a complementary mounting interface at the distal end of the robotic arm. The robotic arm may be capable of automatically docking with different end effectors positioned at a tool-change station adjacent the pallet transfer station (94). The control system (14) mayinstruct the robotic arm to couple with a selected end effector type prior to handling a particular case unit type.

[0112] This interchangeable end effector arrangement provides flexibility in handling heterogeneous case units without requiring separate robotic arms for each end effector type. The control system may dynamically select and attach different end effectors based on identified case unit characteristics, thereby enabling the same robotic arm to perform multiple handling modes. Rather than providing interchangeable tooling at a single pallet transfer station, a plurality of pallet transfer stations may each comprise a robotic arm permanently equipped with a specific end effector type. In such arrangements, pallets and carriers may be transported between stations so that different case unit types are handled by the appropriate station.

[0113] The plurality of pallet transfer stations (94) may include a first set of stations configured primarily for de-palletisation and a second set configured primarily for consolidation. Alternatively, each pallet transfer station may be configured to perform both de-palletising and consolidation operations. In such cases, the robotic arm at a pallet transfer station may operate in the de-palletising mode when receiving inbound pallets and in the consolidation mode when loading carriers (95) with case units retrieved from the buffer (88).

[0114] The control system (14) coordinates operation of the pallet transfer stations, robotic arms, autonomous pallet movers, and load handling devices (36). When a scheduled order is generated, the control system determines which case units are required and retrieves storage containers (34) accordingly. During consolidation, a carrier (95) may be transported sequentially between multiple pallet transfer stations equipped with different end effector types to enable loading of a heterogeneous mixture of case units.

[0115] This multi-station and multi-end-effector architecture enables the system to handle case units of differing dimensions, weight distributions, rigidity characteristics, and packaging geometries while maintaining high throughput and minimising manual intervention.

[0116] To maximise utilisation of the internal volume of each storage container (34), the pallet transfer station (94) may comprise a lifting mechanism configured to cooperate with a storage container (34b), as illustrated in Figure 19. The lifting mechanism enables one or more case units (92) to be positioned at different vertical levels relative to a bottom wall of the storage container so that multiple layers of case units can be accommodated within a single storage container while maintaining accessibility to the vision-assisted robotic arm (96a, 96b).In the illustrated example, the lifting mechanism comprises one or more push rods (150) aligned with one or more corresponding openings (152) formed in the bottom wall of the storage container (34b). The push rods (150) are connected to a drive mechanism configured to extend and retract the push rods in a vertical direction. The drive mechanism may comprise an electric linear actuator, screw drive, pneumatic cylinder, hydraulic actuator, or equivalent vertically actuated mechanism capable of controlled indexed movement.

[0117] When the storage container (34b) is positioned above the lifting mechanism, extension of the push rods (150) through the openings (152) causes one or more case units supported within the storage container to be raised relative to the bottom wall. In certain examples, the storage container may comprise a movable base plate positioned within the internal volume of the container. The base plate is configured to cooperate with the push rods (150), such that vertical movement of the push rods causes corresponding vertical movement of the base plate and the case units supported thereon.

[0118] By raising the base plate and the case units to a presentation height at or above the upper rim of the storage container, the case units are made more accessible to the vision-assisted robotic arm (96a, 96b). In this raised configuration, the robotic arm is not required to extend deeply into the container cavity to grasp the case unit. This reduces the vertical reach requirement of the robotic arm, improves cycle time, reduces collision risk with container walls, and enables reliable handling of case units having different physical characteristics.

[0119] The lifting mechanism may be operated in an indexed manner. After a first case unit is placed on the base plate, the push rods retract to lower the base plate by a predetermined increment corresponding to the thickness of the case unit. A second case unit may then be placed onto the lowered base plate, and the process repeated. In this way, multiple case units can be stacked in vertically arranged layers within a single storage container. The number of layers accommodated depends on container depth, case unit height, and load constraints.

[0120] In addition to vertical movement, lateral transfer of case units onto and from the base plate may be facilitated by a push / pull device. The push / pull device may comprise the robotic arm itself or a separate actuator configured to apply a horizontal force to a case unit when the base plate is positioned at a presentation height. For example, once the push rods (150) raise the base plate above the rim of the storage container, the robotic arm (96a) may slide a case unit laterally onto the base plate rather than lowering the case unit vertically into the container. After placement, the push rods retract to lower the base plate and create space for the next layer.The lifting mechanism may be integrated with the conveyor system (100a, 100b, 100c, lOOd) at the pallet transfer station. In one arrangement, the lifting mechanism is positioned beneath a section of the conveyor system so that storage containers transported along the conveyor pass directly above the lifting mechanism. When a storage container is aligned above the lifting mechanism, the push rods extend upwardly through the openings (152) to raise the case units for loading or unloading. This integration enables in-line operation without requiring removal of the storage container from the conveyor.

[0121] For example, during de-palletisation at station (86), empty storage containers are delivered via the first conveyor (100a) to a position above the lifting mechanism. The push rods may extend to position the base plate at a defined loading height. The robotic arm (96a) then transfers a case unit laterally onto the base plate. After placement, the push rods retract to lower the base plate by an indexed increment. The sequence repeats until the storage container is filled to a desired capacity. The loaded storage container is then conveyed to the pick-up port column (102a) for induction into the grid framework structure (31).

[0122] Similarly, during consolidation at station (90), storage containers retrieved from the buffer (88) are delivered via the second conveyor (100b) to a position above the lifting mechanism. The push rods extend to raise the uppermost case unit to a presentation height. The robotic arm (96b) engages and removes the case unit for transfer to the carrier (95). After removal, the push rods extend further to raise the next case unit in sequence. This process continues until all required case units have been removed from the storage container.

[0123] The lifting mechanism therefore supports both inbound loading and outbound unloading operations. It enables high-density layered packing of case units within storage containers while maintaining robotic accessibility.

[0124] The lifting mechanism also improves system scalability. Because case units are layered within storage containers, the effective storage capacity of the grid framework structure (31) increases without increasing footprint. This contributes to higher cubic storage density within the buffer (88).

[0125] The lifting mechanism may be configured to cooperate selectively with different container formats. For example, storage containers may be provided with different bottom opening geometries to accommodate specific push rod configurations. The push rods may be actuated individually or collectively depending on container width or load distribution requirements.The control system (14) coordinates operation of the lifting mechanism with the robotic arm and conveyor movement. The control system may monitor container position via sensors to ensure correct alignment before actuation of the push rods. Safety interlocks may prevent extension of push rods when no container is present.

[0126] Where case units comprise open trays containing multiple goods, the lifting mechanism may also support goods-level transfer operations. By raising the tray to a presentation height, individual goods can be removed by a robotic arm or transferred between trays without removing the entire case unit from the container.

[0127] The layered loading capability enabled by the lifting mechanism reduces the number of storage containers required to fulfil a scheduled order, reduces retrieval cycles by load handling devices (36), and increases the effective storage density of the grid framework structure (31). By presenting case units at controlled vertical heights, the lifting mechanism also allows simplified robotic configurations and improves cycle efficiency.

[0128] Through coordinated integration of the lifting mechanism, robotic arms (96a, 96b), conveyors (100a, 100b), port columns (102a, 102b), and load handling devices (36), the re-distribution centre achieves efficient vertical and horizontal management of case units within the buffer. Once storage containers (34) containing required case units (92) have been retrieved from the buffer (88) and delivered to the consolidation station (90), the case units are transferred to a carrier (95). The carrier (95) may take multiple forms depending on transport requirements, stacking constraints, and downstream handling infrastructure.

[0129] Figures 20 and 21 illustrate one carrier example in the form of a three-sided enclosure (95). The carrier comprises a base wall (116) and first, second and third side walls (118) extending upwardly from the base wall to define a containment volume (120). One side remains open, forming an opening (122) through which case units are inserted during consolidation.

[0130] The three side walls (118) restrain case units laterally during transport within the re-distribution centre and during outbound delivery. The open side (122) allows unobstructed loading by the vision-assisted robotic arm (96b) during consolidation.

[0131] The base wall (116) may be elevated above the ground by a plurality of legs (112) positioned at comer regions of the carrier. The legs define a clearance space beneath the base wall sized to permit an automated guided vehicle (124), as illustrated in Figure 20, to travel underneathand lift the carrier clear of the ground for transport between pallet transfer stations (94), consolidation stations (90), staging areas, or outbound dispatch areas.

[0132] In alternative arrangements, the base wall (116) may be configured to receive forks of a pallet mover or forklift-type device. In this configuration, the same pallet mover used to transport inbound pallets (84) to the de-palletising station (86) may also be used to transport carriers (95) to consolidation or outbound locations.

[0133] The three-sided carrier is particularly suited for mixed-SKU consolidation where case units of different dimensions are interleaved within the containment volume. The open front permits controlled insertion and arrangement of case units in a predetermined cubing pattern.

[0134] In further examples, the carrier may comprise a stackable stillage (160), as illustrated in Figures 21 and 22. The stillage comprises a frame structure (162) including a base frame (164) and a top frame (166) connected by vertical comer members (168). The comer members define a cuboidal storage space (170) within which case units are arranged.

[0135] As illustrated in Figure 23, a support platform (172) may positioned within the storage space (170) and is vertically movable relative to the base frame (164) by means of a lifting mechanism (176). The lifting mechanism may comprise a scissor lift assembly, screw drive, hydraulic actuator, or equivalent vertical actuation mechanism. The lifting mechanism enables indexed vertical positioning of the support platform to present successive layers of case units to the robotic arm (96b) during consolidation.

[0136] The stillage may further include bracing members (180) extending between the comer members (168) to increase structural rigidity. Stacking features such as feet and complementary head structures may be provided at the distal ends of the comer members to enable vertical stacking of multiple stillages. When stacked, compressive loads are transferred through the frame structure rather than through the case units contained within the storage space.

[0137] The stillage configuration provides advantages over conventional pallets, particularly where case units are fragile or compressible. Because stillages can be stacked vertically without transmitting compressive loads to case units, vehicle transport and warehouse storage can be optimised in both horizontal and vertical directions.

[0138] During consolidation, case units are transferred from retrieved storage containers (34) into the carrier (95) or stillage (160) by the vision-assisted robotic arm (96b). A plurality of case units is arranged to form multiple layers within the carrier volume.Figure 24 illustrates example packing patterns that may be employed to maximise cube utilisation. In one example, a spiral configuration is used, whereby case units are arranged in a rotating sequence to optimise space utilisation. In another example, a brick-pattern configuration is used, in which case units are arranged in overlapping rows to minimise void spaces between adjacent case units.

[0139] The control system (14) may implement cubing algorithms to determine optimal placement of case units within the carrier footprint. These algorithms consider:

[0140] • Dimensions of each case unit,

[0141] • Weight distribution,

[0142] • Carrier footprint dimensions,

[0143] • Maximum allowable stacking height,

[0144] • Structural constraints of the carrier,

[0145] • Stability requirements during transport.

[0146] The objective is to approach full cube utilisation, meaning that the carrier volume defined by its footprint and allowable height is filled with minimal unused space.

[0147] In order to ensure efficient transport utilisation, consolidation may be controlled to achieve a minimum carrier density. Carrier density may be defined as the total mass of case units loaded divided by the volumetric space occupied by the carrier. In certain examples, the carrier density is required to be at least 0.1 tonnes per cubic metre and preferably at least 0.3 tonnes per cubic metre.

[0148] The control system (14) may determine whether the number of case units specified in a scheduled order exceeds a predetermined threshold corresponding to the minimum quantity required to adequately fill the carrier both horizontally and vertically. Where the quantity falls below the threshold, consolidation may be deferred until additional case units are available or multiple scheduled orders may be combined to achieve sufficient density.

[0149] By enforcing density thresholds, the system reduces the number of outbound shipments required to fulfil forecast demand, thereby improving transport efficiency and reducing operational costs.

[0150] Once consolidation is complete, the carrier (95) may be transported to an outbound staging area within the re-distribution centre (4). Transport may be carried out by automated guided vehicles (124), pallet movers, or forklifts, depending on the carrier configuration.In some examples, as shown in Figure 20, the automated guided vehicle (124) travels beneath the elevated base wall (116) and lifts the carrier by engaging its underside. In alternative examples, forklift tines engage fork-receiving openings in the base wall.

[0151] The consolidated carrier may then be transported to a fulfilment centre (6) for further processing, or, in certain examples, may be returned to the same grid framework structure (31) if a single-grid example is employed. In the latter case, consolidated case units may undergo de-trashing and decanting into goods before being stored in a second portion of the same grid framework structure.

[0152] The system may also permit container-level consolidation, whereby entire storage containers (34) are loaded directly into the carrier (95) without removing case units individually. In such examples, the end effector of the robotic arm (96b) is configured to engage the storage container using engagement features analogous to those of the grabber device (68). This approach is advantageous where storage containers are compatible between the re-distribution centre grid (31) and a downstream grid framework structure (112) at a fulfilment centre. The combination of heterogeneous end effector handling, layered container loading discussed above, cubing algorithms, density thresholds, and structured carrier examples enables:

[0153] • Reduced pallet retrieval cycles,

[0154] • Improved volumetric storage efficiency,

[0155] • Optimised transport capacity,

[0156] • Reduced manual handling,

[0157] • Enhanced scalability of redistribution operations.

[0158] The re-distribution centre (4) therefore functions not merely as a storage warehouse but as an active consolidation and sequencing facility capable of dynamically reorganising case units to match forecasted downstream demand.

[0159] The operation of the re-distribution centre (4) is coordinated by the control system (14), which governs the movement of pallets (84), storage containers (34), load handling devices (36), robotic arms (96a, 96b), carriers (95), and associated transport mechanisms. Figures 25 and 26 illustrate representative control processes implemented by the control system to manage depalletisation and consolidation operations, particularly in scenarios involving mixed case-unit types and heterogeneous handling requirements.Figure 25 illustrates a control process (200) for de-palletising pallets that may comprise one or more types of case units having different physical characteristics.

[0160] The process begins at Step (202), when a pallet (84) arriving at the staging area (84) and subsequently positioned at a de-palletising station (86) is registered by the control system (14). At Step (204), the control system acquires data identifying the physical characteristics of the case units (92) present on the pallet. This information may be obtained from label scanning, vision-based dimensional analysis, supplier metadata, or stored SKU information.

[0161] At Step (206), the control system determines whether the pallet comprises a single case-unit type or multiple case-unit types. If a single case-unit type is detected, the process proceeds to Step (208), in which the control system determines the appropriate end effector type capable of handling that case unit. At Step (210), the control system instructs a transport mechanism, such as an autonomous pallet mover, to move the pallet (84) to a pallet transfer station (94) equipped with the compatible end effector.

[0162] Once positioned, Step (212) is executed, in which the vision-assisted robotic arm (96a) removes compatible case units (92) from the pallet (84) and transfers them into storage containers (34). After each transfer cycle, Step (216) determines whether additional case units of the same type remain on the pallet. If so, Step (212) is repeated until that case-unit type has been fully depalletised.

[0163] If, at Step (206), multiple case-unit types are identified, the process proceeds to Step (214), where the control system generates a routing sequence identifying a plurality of pallet transfer stations (94), each configured with an end effector suitable for handling a respective case-unit type. The pallet (84) is then transported according to Step (210) to the first pallet transfer station in the routing sequence.

[0164] At each pallet transfer station, Step (212) is executed for the compatible case-unit type. Following removal of those case units, Step (216) evaluates whether incompatible case-unit types remain on the pallet. If additional types remain, the process returns to Step (210) and the pallet is transported to the next pallet transfer station in the routing sequence. This iterative loop continues until all case units have been removed from the pallet.

[0165] At Step (218), storage containers (34) loaded with case units are transported via the first conveyor (100a) to the pick-up port column (102a) and inducted into the grid framework structure (31) by one or more load handling devices (36).Through execution of Steps (202) through (218), the control system (14) enables automated de-palletisation of pallets comprising heterogeneous case-unit types without manual segregation and ensures that each case-unit type is handled by an appropriate end effector. Figure 26 illustrates a consolidation control process (300) executed by the control system (14) in response to a scheduled order.

[0166] The process begins at Step (302), when the control system generates or receives a scheduled order specifying required SKU types and quantities for a fulfilment centre (6) or other downstream destination. At Step (304), an empty carrier (95) is allocated and positioned at a consolidation station (90).

[0167] At Step (306), the control system analyses the scheduled order to determine the physical characteristics of the case units required. At Step (308), the control system determines whether the scheduled order comprises a single case-unit type or multiple case-unit types.

[0168] If a single case-unit type is required, the process proceeds to Step (310), where the carrier (95) is transported to a pallet transfer station (94) equipped with an end effector compatible with the required case-unit type. If multiple case-unit types are required, the process proceeds to Step (312), where the control system generates a routing sequence identifying a plurality of pallet transfer stations (94), each configured to handle a different case-unit type.

[0169] At Step (314), the control system instructs a carrier transport mechanism to move the carrier (95) to the first pallet transfer station in the routing sequence.

[0170] In parallel, at Step (316), the control system instructs one or more load handling devices (36) to retrieve target storage containers (34) from the buffer (88) that contain the required case units. At Step (318), the retrieved storage containers are delivered via the drop-off port column (102b) to the consolidation station (90).

[0171] At Step (320), the vision-assisted robotic arm (96b) transfers compatible case units (92) from the retrieved storage containers into the carrier (95). During this step, the control system monitors cumulative volume and mass to ensure that cube utilisation and density thresholds are achieved.

[0172] At Step (322), the control system determines whether additional case-unit types remain to be consolidated for the scheduled order. If additional types remain, the process returns to Step(314), and the carrier (95) is transported to the next pallet transfer station in the routing sequence, where Steps (316) through (320) are repeated.

[0173] Throughout execution of Process (200) and Process (300), the control system (14) applies prioritisation logic. If multiple scheduled orders are active, the control system may dynamically reorder execution of Steps (210) and (314) to prioritise urgent fulfilment centre replenishment. Throughout consolidation, the control system monitors cumulative carrier density and volume utilisation. If the number of case units retrieved does not meet the predetermined density threshold, the control system may instruct retrieval of additional case units from the buffer before releasing the carrier for dispatch. Once consolidation is complete and density criteria are satisfied, the carrier is transported to an outbound staging area or directly to a fulfilment centre.

[0174] The control system employs routing algorithms to optimise movement of pallets, carriers, and storage containers. These algorithms consider factors including:

[0175] • Physical characteristics of case units,

[0176] • Availability of pallet transfer stations,

[0177] • End effector compatibility,

[0178] • Current load handling device positions,

[0179] • Scheduled departure times of outbound carriers,

[0180] • Urgency of fulfilment centre replenishment,

[0181] • Buffer occupancy levels,

[0182] • Travel distance minimisation within the grid.

[0183] The routing logic may prioritise consolidation for fulfilment centres experiencing critical stock shortages. It may also dynamically reassign load handling devices to reduce congestion at port columns (102a, 102b).

[0184] Parallel processing may be implemented by allocating multiple load handling devices to retrieve storage containers for different scheduled orders simultaneously. Where multiple port columns are available, retrieval streams may be distributed across port columns to avoid bottlenecks.

[0185] The control system (14) is configured to detect and respond to failure conditions within the redistribution system. For example, if a load handling device (36) becomes inoperative, retrieval tasks assigned to that device may be reallocated to other load handling devices within the gridframework structure (31). The control system may maintain a queue of pending retrieval operations and dynamically reschedule them to maintain throughput.

[0186] If a robotic arm (96a, 96b) at a pallet transfer station (94) becomes unavailable, the control system may reroute pallets or carriers to alternative pallet transfer stations equipped with compatible end effectors. Where end effectors are interchangeable, the control system may instruct a robotic arm to switch tooling in response to an equipment fault.

[0187] The system may also monitor sensor feedback from lifting mechanisms, conveyors (100a, 100b), and push rods (150) to detect misalignment or obstruction. In the event of a detected fault, motion may be halted and corrective actions initiated.

[0188] Redundancy may be achieved by providing multiple pallet transfer stations and multiple load handling devices operating concurrently on the grid framework structure. Logical partitioning of the grid may allow isolated sections to continue operation even if another section requires maintenance.

[0189] The control system may operate in different modes depending on operational conditions. In a high-throughput mode, case units may be transferred directly from inbound pallets to outbound carriers with minimal buffering when SKU homogeneity permits. In a sequencing-optimised mode, case units are fully inducted into the grid framework structure and reorganised extensively prior to consolidation.

[0190] The control system may also implement hybrid scheduling in which goods-level transfers performed by on-grid robotic pick stations (37) reduce the number of storage containers retrieved for consolidation, thereby increasing efficiency.

[0191] All de-palletisation and consolidation processes are coordinated with the inventory management system (12). The scheduled order generation process accounts for forecasted consumption over a predetermined period of time, enabling consolidation of case units in anticipation of demand rather than reacting only after stock depletion.

[0192] Where a fulfilment centre (6) has surplus stock of a given SKU type while another fulfilment centre experiences a shortage, the control system may instruct retrieval and consolidation of case units for redistribution between fulfilment centres. In this manner, the buffer (88) functions as a central stock balancing and redistribution hub.Through coordinated implementation of routing algorithms, dynamic sequencing within the grid framework structure (31), heterogeneous end effector selection, layered container loading, cubing-based consolidation, and forecast-driven scheduling, the re-distribution centre (4) achieves:

[0193] • Predictive consolidation of mixed-SKU shipments,

[0194] • Reduced pallet handling and manual intervention,

[0195] • Improved volumetric storage density,

[0196] • Reduced outbound shipment frequency,

[0197] • Balanced load handling across the grid,

[0198] • Increased system resilience to component failures.

[0199] The expanded control logic ensures that the re-distribution centre operates as an intelligent, dynamically managed logistics platform rather than a passive storage facility.

[0200] While the preceding examples describe separate grid framework structures for the redistribution centre (4) and for one or more fulfilment centres (6), the sorting, sequencing and retrieval operations of both facilities may alternatively be carried out using a single storage and retrieval system implemented as a grid framework structure (31). This shared-grid example is illustrated schematically in Figure 8.

[0201] In this arrangement, the grid framework structure (31) is logically partitioned into at least two functional regions. A first portion of the grid framework structure is allocated for storing and sequencing case units (92) within storage containers (34) for redistribution and consolidation into carriers (95). A second portion of the grid framework structure is allocated for storing goods or eaches following de-trashing of case units and for supporting downstream picking operations.

[0202] Case units consolidated onto carriers (95) are first de-trashed at a de-trash station (108), as described previously with reference to Figure 7(B). At the de-trash station (108), outer packaging is removed to expose the goods contained within the case units. The goods are then transferred to a decant station (110), where they are decanted into storage containers (34) before being inducted into the second portion of the grid framework structure (31) for storage.

[0203] In operation, inbound pallets (84) are de-palletised at the de-palletising station (86), and case units (92) are transferred into storage containers (34) for storage in the first portion of the gridframework structure (31). Load handling devices (36) position these storage containers within storage columns according to sequencing instructions from the control system (14).

[0204] When a scheduled order requires palletised case units for dispatch to a fulfilment centre (6), the control system instructs one or more load handling devices (36) to retrieve target storage containers (34) from the first portion of the grid. The retrieved storage containers are delivered to the consolidation station (90), where the case units are consolidated into carriers (95). The consolidated carriers may then be transported either to an external fulfilment centre (6) having a separate grid framework structure (112) or to a de-trash station (108) located within the same facility.

[0205] Where the consolidated carriers are processed within the same facility, case units are de-trashed and the goods are decanted into storage containers (34) for storage in the second portion of the grid framework structure (31). Load handling devices (36) operating on the same track system (46) then retrieve target storage containers containing goods required for one or more customer orders and transfer them to a pick station (114).

[0206] This shared-grid architecture enables a single grid framework structure (31) and a single fleet of load handling devices (36) to support both case-unit-level redistribution and goods-level fulfilment operations. Logical partitioning of the grid may be implemented via control software rather than physical barriers, allowing dynamic allocation of storage columns between caseunit storage and goods storage depending on operational requirements.

[0207] The grid framework structure (31) can be further configured to accommodate case units comprising temperature sensitive goods, e.g., frozen or chilled goods. In such arrangements, the grid framework structure (31) may be logically partitioned so that a designated portion operates as a temperature-controlled region, for example a chilled or freezer portion, while another portion operates at ambient temperature. The temperature-controlled portion may be maintained by one or more refrigeration units, cooling coils, or forced-air blowers configured to circulate conditioned air within the defined region of the grid framework structure (31). Alternatively, frozen or chilled case units may be stored within a separate grid framework structure located within a temperature-controlled enclosure. In either configuration, storage containers (34) containing frozen or chilled case units are inducted into the temperature-controlled portion of the grid and are handled by load handling devices (36) in the same manner as described above. The control system (14) sequences and retrieves the storage containers in anticipation of scheduled orders using the same routing logic, prioritisation, and consolidationprocesses previously described, with the additional constraint that temperature-sensitive case units remain within the controlled environment until transfer to a carrier (95) for transport. In addition to the pallet transfer stations (94) located at the periphery of the grid framework structure (31), the system may further comprise one or more on-grid robotic pick stations (37), as illustrated in Figures 11 and 12. Each on-grid robotic pick station (37) comprises a vision-assisted robotic arm mounted directly on the track system (46) or integrated into the grid framework structure (31).

[0208] The on-grid robotic pick station (37) is configured to access storage containers (34) positioned within storage columns without requiring the containers to be transported to an external pallet transfer station. The robotic arm associated with the on-grid robotic pick station is capable of lowering into a grid cell and engaging case units (92) or individual goods within a storage container.

[0209] The primary function of the on-grid robotic pick station is to enable intra-buffer transfer of case units and goods between storage containers. In a first tier of operation, the load handling devices (36) perform spatial reordering of storage containers across the grid framework structure. In a second tier of operation, the on-grid robotic pick station performs localised reordering of case units or goods between storage containers.

[0210] For example, if a scheduled order requires ten case units of a particular SKU type and those case units are distributed across five different storage containers within the grid, the control system (14) may instruct the on-grid robotic pick station (37) to transfer case units from multiple storage containers into a single target storage container. This consolidation at container level reduces the number of containers that must subsequently be retrieved to the consolidation station (90), thereby reducing load handling cycles and improving throughput. In addition to case-unit-level transfer, the on-grid robotic pick station (37) may perform goods-level transfer. One or more case units may comprise trays or crates containing individual goods that are accessible without removing the entire case unit from the storage container. In such circumstances, the robotic arm may remove one or more goods from a first tray or crate while the tray or crate remains in situ within its respective storage container, and transfer those goods to a second tray or crate located within another storage container. This goods-level in situ transfer enables precise preparation of storage containers containing specific quantities or mixtures of SKU types that may not correspond to full case units.Goods-level transfer supports partial-order fulfilment scenarios in which the scheduled order requires fewer goods than contained in a complete case unit. Rather than retrieving and opening entire case units, the system may redistribute goods between containers within the grid so that storage containers contain exactly the required quantities for consolidation or picking.

[0211] The on-grid robotic pick station may utilise end effector types similar to those described above, including suction-based and mechanically clamping end effectors, selected according to the physical characteristics of the goods or case units being handled. The vision system associated with the robotic arm identifies the position and orientation of case units or goods within storage containers to enable reliable engagement.

[0212] By combining container-level repositioning via load handling devices (36) and case-unit-level or goods-level transfer via on-grid robotic pick stations (37), the buffer (88) functions as a multi-tier sequencing engine. At a macro level, containers are spatially repositioned within the grid; at a micro level, contents of containers are reorganised without external retrieval. This dual-level sequencing significantly reduces unnecessary movement, improves container fill ratios, and increases effective storage density within the grid framework structure (31).

[0213] In the shared-grid example, the control system (14) dynamically allocates storage columns between the first portion (case-unit storage) and the second portion (goods storage). During periods of high redistribution activity, a greater proportion of the grid may be allocated to caseunit storage. During peak fulfilment periods, more columns may be allocated to goods storage. The control system also coordinates prioritisation of tasks across redistribution and fulfilment operations. For example, urgent fulfilment centre replenishment may be prioritised over routine redistribution, and goods-level picking may be prioritised during high customer order volumes. The single-grid example provides several technical advantages. First, infrastructure is shared between redistribution and fulfilment operations, reducing capital expenditure and floor space requirements. Second, load handling devices (36) and robotic arms (96a, 96b, 37) are utilised more efficiently through centralised scheduling. Third, multi-tier sequencing within the grid reduces the number of container retrieval operations required to fulfil scheduled orders. Fourth, goods-level in situ transfer reduces waste associated with opening full case units when only partial quantities are required.

[0214] By integrating the grid framework structure (31), load handling devices (36), pallet transfer stations (94), heterogeneous end effector systems, lifting mechanisms (150), carriers (95),stillages (160), cubing algorithms, routing logic, and on-grid robotic pick stations (37), the redistribution centre (4) operates as a highly flexible, high-density, predictive logistics platform. The system enables proactive consolidation of mixed-SKU shipments in anticipation of scheduled downstream demand while simultaneously supporting goods-level fulfilment operations.

[0215] The examples described herein are illustrative and not limiting. Variations in grid size, number of pallet transfer stations, number of on-grid robotic pick stations, configuration of port columns, and routing algorithms may be implemented without departing from the scope defined by the appended claims.

Claims

Claims1. A re-distribution system for consolidating a plurality of case units from a plurality of pallets in a fulfilment centre to one or more carriers in anticipation of a scheduled order of a plurality of case units, said plurality of case units comprising a mixture of case units of different SKU types, each of the plurality of case units comprising a plurality of goods,said re-distribution system comprising:A) a buffer; said buffer comprising a grid framework structure comprising a plurality of storage columns for the storage of a plurality of storage containers in one or more stacks, a track system arranged above the plurality of storage columns, said track system comprising a first set of parallel tracks extending in an X-direction, and a second set of parallel tracks extending in a Y-direction transverse to the first set of parallel tracks in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces or grid cells, at least one port column extending downwardly from a grid cell through which one or more storage containers can be dropped off and / or picked-up from the buffer,B) one or more load handling devices operable to move one or more of the storage containers within the buffer;C) a pallet transfer station comprising at least one vision-assisted robotic arm;D) a control system comprising one or more processors and memory storing instructions that when executed by the one or more processors cause the control system to:a) instruct the at least one vision-assisted robotic arm to move one or more of the plurality of the case units between one or more pallets and one or more storage containers;b) instruct the one or more load handling devices operating on the track system to retrieve one or more storage containers from the buffer in anticipation of the scheduled order; and c) instruct the at least one vision-assisted robotic arm to move one or more of the plurality of case units retrieved between the buffer and the one or more carriers such that each of the one or more carriers comprises a consolidated mix of case units of different SKU types.

2. The re-distribution system of claim 1, wherein the at least one vision-assisted robotic arm comprises a first vision-assisted robotic arm and a second vision-assisted robotic arm, said control system being configured to:i) instruct the first vision-assisted robotic arm to transfer one or more of the plurality of the case units from one or more of the pallets to one or more of the plurality of storage containers for storage in the buffer; andii) instruct the second vision-assisted robotic arm to transfer one or more of the plurality of the case units and / or one or more of the plurality of storage containers comprising one or more of the case units retrieved from the buffer to one or more of the carriers.

3. The re-distribution system of claim 1, further comprising a plurality of different types of end effectors to handle a different type of case unit, each of the plurality of the different types of end effectors being configured to interface with the at least one vision-assisted robotic arm, said control system being configured to select different types of end effectors to:a) transfer different types of case units between the one or more pallets and one or more storage containers; andb) transfer different types of case units between the one or more storage containers retrieved from the buffer and one or more carriers such that each of the one or more carriers comprises a mixture of case units of different SKU types.

4. The re-distribution system of claim 3, wherein the plurality of end effectors comprises a first type end effector and a second type end effector, wherein the first type end effector comprises a suction cup and the second type end effector comprises a mechanical gripper.

5. The re-distribution system of claim 1, wherein the at least one vision-assisted robotic arm comprises a plurality of vision-assisted robotic arms, each of the plurality of vision-assisted robotic arms comprises a different type of end effector configured to handle a different type of case unit, said control system being configured to instruct the plurality of vision-assisted robotic arms to:a) transfer different types of case units between the one or more pallets and one or more storage containers; andb) transfer different types of case units between the one or more storage containers retrieved from the buffer and one or more carriers such that each of the one or more carriers comprises a mixture of case units of different SKU types.

6. The re-distribution system of claim 5, wherein the plurality of vision-assisted robotic arms comprises a first type vision-assisted robotic arm and a second type vision-assisted robotic arm, wherein the end effector of the first type vision-assisted robotic arm comprises a suction cup and the end effector of the second type vision-assisted robotic arm comprises a mechanical gripper.

7. The re-distribution system of claim 5 or 6, wherein the pallet transfer station comprises a plurality of pallet transfer stations at different locations, each of the plurality of pallet transfer stations comprising at least one vision-assisted robotic arm, the at least one vision-assisted robotic arm of each of the plurality of pallet transfer stations comprising an end effector of a different type from the vision-assisted robotic arms at the other pallet transfer stations, each end effector being configured to handle a respective type of case unit.

8. The re-distribution system of claim 7, wherein the at least one port column comprises a plurality of port columns, wherein each of the plurality of port columns is associated with a respective one of the plurality of pallet transfer stations through which one or more load handling devices operable on the track system can drop-off and / or pick-up one or more storage containers to and / or from that respective pallet transfer station via that respective port column.

9. The re-distribution system of claim 7 or 8 wherein the plurality of vision-assisted robotic arms comprises a first set of vision-assisted robotic arms and a second set of vision-assisted robotic arms, said control system being configured to instruct the first set of vision-assisted robotic arms to transfer different types of case units between the one or more pallets and one or more storage containers and the second set of vision-assisted robotic arms to transferdifferent types of case units between the one or more storage containers and the one or more carriers.

10. The re-distribution system of claim 9, wherein the plurality of pallet transfer stations comprises a plurality of de-palletising stations and a plurality of consolidation stations, said first set of vision-assisted robotic arms being distributed amongst the plurality of de-palletising stations such that the vision-assisted robotic arm at each of the plurality of de-palletising stations comprises a different type of end effector, and the second set of vision-assisted robotic arms being distributed amongst the plurality of consolidation stations such that the vision-assisted robotic arm at each of the plurality of consolidation stations comprises a different type of end effector.

11. The re-distribution system of any of the claims 7 to 10, further comprising one or more automated pallet movers, said control system being configured to control the one or more automated pallet movers to move one or more pallets and / or carriers between each of the plurality of the pallet transfer stations.

12. The re-distribution system of any one of the preceding claims, comprising a conveyor system configured to transport a storage container between the at least one port column and the pallet transfer station for accessing the contents of the storage container external of the grid framework structure.

13. The re-distribution system of any one of the preceding claims, wherein the pallet transfer station comprises a lifting mechanism configured to cooperate with a storage container to move one or more case units vertically relative to a bottom wall of the storage container.

14. The re-distribution system of claim 13, wherein the lifting mechanism comprises a push rod configured to cooperate with an opening in the bottom wall of the storage container and a drive mechanism to extend the push rod vertically within the storage container such that one or more case units are moveable vertically relative to the bottom wall of the storage container.

15. The re-distribution system of claim 14, wherein one or more storage containers comprise a base plate housed within the storage container and configured to support one or more case units, wherein the base plate is configured to cooperate with the push rod such that the drive mechanism is configured to move the base plate relative to the bottom wall of the storage container.

16. The re-distribution system of any one of the preceding claims, wherein at least one of the one or more carriers comprises a pallet or roll cage.

17. The re-distribution system of any one of the preceding claims, wherein the pallet transfer station comprises a pallet lifting device, said pallet lifting device comprising a pallet support for supporting a pallet, and a lifting drive mechanism configured to move the pallet support in a vertical direction, said control system in cooperation with the lifting drive mechanism being operable to control the movement of the pallet support in the vertical direction.

18. The re-distribution system of any one of the preceding claims, wherein one or more of the plurality of case units comprise a plurality of goods or items of a single SKU type.

19. The re-distribution system of any of the preceding claims, further comprising an inventory handling station configured to move one or more goods between storage containers.

20. The re-distribution system of claim 19, wherein the inventory handling station comprises an on-grid robotic pick station mounted on the track system, said on-grid robotic pick station comprising a vision-assisted robotic arm configured to move the one or more goods between storage containers within the buffer.

21. A system comprising:A) a re-distribution centre comprising a re-distribution system as defined in any one of the claims 1 to 20;B) at least one fulfilment centre, said at least one fulfilment centre being configured to fulfil one or more customer orders comprising one or more SKU types;C) an inventory management system comprising:i) a stock database comprising data indicative of the quantity of stock comprising a plurality of SKU types at the re-distribution centre and at the at least one fulfilment centre;ii) a control unit in communication with the stock database being configured to provide instructions to the control system of the re-distribution system to replenish stock at the at least one fulfilment centre in response to a stock level of the one or more SKU types at the at least one fulfilment centre being below a predetermined number of case units.

22. The system of claim 21, wherein the control unit is configured to provide instructions to the control system to replenish stock at the at least one fulfilment centre when one or more repalletised pallets have a packing density of greater than 100 kg / m3.

23. The system of claim 21 or 22, wherein the scheduled order comprises data associated with a forecasted consumption of the plurality of the different SKU types in a predetermined period of time at the at least one fulfilment centre.

24. The system of any one of the claims 21 to 23, wherein the inventory management system in anticipation of the scheduled order at the at least one fulfilment centre is configured to generate a set of instructions to the control system of the re-distribution system to request the one or more consolidated carriers from the re-distribution centre by causing the control system to:i) instruct one or more load handling devices operative on the grid framework structure to retrieve one or more storage containers from the grid framework structure, each of the one or more storage containers comprising one or more of the case units of the scheduled order; andii) instruct the at least one vision-assisted robotic arm to transfer one or more of the case units from each of the one or more storage containers retrieved from the grid framework structure to the one or more carriers allocated to the at least one fulfilment centre such that each of the one or more carriers comprises a consolidated mix of different SKU types.

25. The system of any one of the claims 21 to 24, wherein the re-distribution centre is configured to fulfil one or more customer orders by sharing stock between the at least one fulfilment centre and the re-distribution centre, said inventory management system being configured to generate a set of instructions to the control system of the re-distribution system to allocate the one or more carriers in anticipation of the one or more customer orders at the redistribution centre.

26. The system of any one of the claims 21 to 25, wherein the re-distribution centre and the at least one fulfilment centre share a single grid framework structure, the grid framework structure being partitioned such that:i) a first portion of the grid framework structure is configured to store and sequence the plurality of case units within storage containers for consolidation and redistribution; andii) a second portion of the grid framework structure is configured to store goods or items for fulfilling of one or more customer orders.

27. The system of any one of the claims 21 to 25, wherein the at least one fulfilment centre comprises:i) a grid framework structure for the storage of goods, said grid framework structure being separate to the grid framework structure of the buffer;ii) one or more robotic load handling devices operable on the grid framework structure to deposit and retrieve one or more goods from the grid framework structure.

28. The system of claim 27, wherein the at least one fulfilment centre comprises a plurality of fulfilment centres, each of the plurality of fulfilment centres being configured to fulfil one or more customer orders comprising one or more SKU types.

29. The system of any one of the claims 21 to 28, wherein the at least one fulfilment centre comprises an inventory handling station operable in cooperation with the grid framework structure for handling one or more goods retrieved by the one or more load handling devices.

30. A method for distributing stock comprising a plurality of case units to one or more fulfilment centres, each of the plurality of case units comprising a plurality of goods of a single SKU type, the method comprising the steps of:i) receiving, at an inventory management system, a request for a scheduled order of a plurality of case units at the one or more of the plurality of fulfilment centres;ii) instructing, by the inventory management system, a re-distribution system as defined in any one of the claims 1 to 20, to retrieve the plurality of case units from the buffer;iii) consolidating the plurality of case units into one or more carriers, each of the one or more carriers comprising a consolidated mixture of case units of different SKU types.

31. The method of claim 30, further comprising the steps of:a) instructing the at least one vision-assisted robotic arm to move one or more of the plurality of the case units between the pallet transfer station and the one or more storage containers; b) instructing one or more load handling devices to deposit the one or more storage containers in the buffer;c) instructing one or more load handling devices operative on the grid framework structure to retrieve one or more storage containers comprising one or more case units of the scheduled order from the buffer; andd) instructing the at least one vision-assisted robotic arm to move one or more of the plurality of the case units from the one or more storage containers retrieved from the buffer to the oneor more carriers such that each of the one or more carriers comprises a consolidated mix of case units of different SKU types.

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