TECHNICAL FIELD

This document relates to systems and methods for enhancing efficiencies of material handling and storage systems. For example, this document relates to systems and methods for enhancing automated material handling and storage systems by facilitating multi-level accessibility of materials moving into and out of a three-dimensional storage and retrieval system.

BACKGROUND

Highly efficient warehousing, item stowage, item picking, order sortation, and shipping processes are on the frontline of meeting high-level customer expectations regarding order fulfillment processes.

The order fulfillment process refers to all the steps companies take from when they receive a customer order (which can include an order that is wholly or partly internal to the company, such as a store replenishment order) until the items are landed in customers' or recipients' hands. Such steps can include, for example: the order is sent to the warehouse; a worker goes into the warehouse, finds the items in the order, and picks the items off the shelf; the order is packed for shipping; the order is shipped.

The use of warehouse automation is one way to increase the efficiency of an order fulfillment process. The goal of automation is to cut out manual steps of the order fulfillment process. Automation technology is useful for at least two reasons: to help reduce the occurrences of human error, and to make order fulfillment processes more efficient.

SUMMARY

This document describes systems and methods for enhancing efficiencies of material handling and storage systems. For example, this document describes systems and methods for enhancing automated material handling and storage systems by facilitating multi-level accessibility of materials moving into and out of a three-dimensional storage and retrieval system.

In one aspect, this disclosure is directed to a three-dimensional (3D) storage system. In some embodiments, the 3D storage system includes multiple storage levels stacked vertically in relation to each other, a top level arranged above an uppermost level of the multiple storage levels, and a bottom level arranged below a lowermost level of the multiple storage levels. Each storage level defines storage cells and open cells. The open cells of each storage level are stacked vertically in relation to each other to define open vertical passageways configured for automated vehicles to travel vertically between the multiple storage levels. The open vertical passageways include peripheral open vertical passageways located at a periphery of the 3D storage structure. The top level comprises an arrangement of upper mechanical members by which the automated vehicles can travel in two dimensions within a top horizontal plane so as to access top ends of the open vertical passageways. The bottom level comprises an arrangement of lower mechanical members by which the automated vehicles can travel in two dimensions within a bottom horizontal plane so as to access bottom ends of the open vertical passageways. The peripheral open vertical passageways are configured to facilitate the automated vehicles to exit, enter, or both exit and enter the 3D storage structure via one or more of the multiple storage levels.

Such a 3D storage system may optionally include one or more of the following features. The open vertical passageways may include interior open vertical passageways that are located in the interior of the 3D storage structure in comparison to the peripheral open vertical passageways. The 3D storage system may also include one or more of the automated vehicles. In some embodiments, each of the one or more automated vehicles is configured to engage and transport a respective storage container. Each of the one or more automated vehicles may include a mechanism for transferring a storage container that is onboard the automated vehicle to a storage cell. The peripheral open vertical passageways may be configured to facilitate the automated vehicles to exit, enter, or both exit and enter the 3D storage structure via each of the multiple storage levels.

In another aspect, this disclosure is directed to another 3D storage system embodiment. The 3D storage system includes multiple storage levels stacked vertically in relation to each other, a plurality of storage containers, a top level arranged above an uppermost level of the multiple storage levels, and a bottom level arranged below a lowermost level of the multiple storage levels. Each storage level defines storage cells and open cells. The open cells of each storage level are stacked vertically in relation to each other to define open vertical passageways configured for automated vehicles to travel vertically between the multiple storage levels. The open vertical passageways include peripheral open vertical passageways located at a periphery of the 3D storage structure. Each storage container configured to be individually received in any one of the storage cells and to be individually transported within the 3D storage structure by any one of the automated vehicles. The top level comprising an arrangement of upper mechanical members by which the automated vehicles can travel in two dimensions within a top horizontal plane so as to access top ends of the open vertical passageways. The bottom level comprising an arrangement of lower mechanical members by which the automated vehicles can travel in two dimensions within a bottom horizontal plane so as to access bottom ends of the open vertical passageways. The peripheral open vertical passageways are configured such that the storage containers can individually exit, enter, or both exit and enter the 3D storage structure via one or more of the multiple storage levels.

Such a 3D storage system may optionally include one or more of the following features. The open vertical passageways may include interior open vertical passageways that are located in the interior of the 3D storage structure in comparison to the peripheral open vertical passageways. The 3D storage system may also include one or more of the automated vehicles. Each of the one or more automated vehicles may be configured to engage and transport a respective storage container. Each of the one or more automated vehicles may include a mechanism for transferring a storage container that is onboard the automated vehicle to a storage cell. The mechanism may also be configured for transferring the storage container that is onboard the automated vehicle to exit the 3D storage structure via one or more of the multiple storage levels. The peripheral open vertical passageways may be configured to facilitate the storage containers to exit, enter, or both exit and enter the 3D storage structure via each of the multiple storage levels.

In another aspect, this disclosure is directed to a method of stowing and retrieving storage containers using automated vehicles operating in a 3D storage structure. The method includes: (i) transporting, by a first automated vehicle, a storage container within the 3D storage structure; (ii) placing, using the first automated vehicle, the storage container into a first storage cell of the 3D storage structure; (iii) retrieving, using a second automated vehicle, the storage container from the first storage cell; (iv) transporting, by the second automated vehicle, the storage container from the first storage cell to a peripheral open vertical passageway; and (v) while the second automated vehicle and the storage container are at the peripheral open vertical passageway, transferring the storage container out of the 3D storage structure from one of the multiple storage levels. In some embodiments, the 3D storage structure includes multiple storage levels stacked vertically in relation to each other. Each storage level defines storage cells and open cells. The open cells of each storage level are stacked vertically in relation to each other to define open vertical passageways configured for the automated vehicles to travel vertically between the multiple storage levels. The open vertical passageways include peripheral open vertical passageways located at a periphery of the 3D storage structure.

Such a method of stowing and retrieving storage containers using automated vehicles operating in a 3D storage structure may optionally include one or more of the following features. In some embodiments, the method also includes inducting the storage container into the 3D storage structure via a particular one of the peripheral open vertical passageways and at a particular one of the multiple storage levels.

The systems and processes described here may be used to provide one or more of the following optional benefits. First, some embodiments provide an inventory storage and retrieval process that is more efficient, responsive, and agile so orders can be shipped to internal and external customers in a shorter timeframe than current processes. Such a result can be accomplished, for example, through optimizing material flow by reducing material handling, storage, and delays related to stowing and retrieving inventoried items. Second, inventory carrying costs can be reduced by the added efficiencies provided by the systems and processes described herein. Third, in some cases warehouse space requirements can be reduced using the automated systems and processes described herein.

Other features, aspects and potential advantages will be apparent from the accompanying description and figures.

