WAREHOUSE FOR ORDER FULFILMENT

A warehouse for order fulfilment with a product storage and at least one order fulfillment level in which picking stations are arranged and supplied with articles from the product storage for picking into order load carriers according to allocated orders wherein each picking station is supplied with articles from the product storage by a connecting conveyor system on the least one order fulfillment level , where each order fulfillment level has at least one further virtual order fulfillment level in which picking stations are arranged at different height from the at least one order fulfillment level.

BACKGROUND AND FIELD OF THE INVENTION

The invention relates to a warehouse for order fulfilment with a product storage and at least one order fulfillment level in which picking stations are arranged and supplied with articles from the product storage for picking into order load carriers according to allocated orders.

Pick performance of picking stations are limited by many factors such as operator efficiency, ergonomics, order/SKU profiles, business rules etc. On the other hand, storage and retrieval systems feeding picking stations from storage racking, such as MultiShuttle, are constantly improving in retrieval performance as technology becomes more sophisticated.

The picking station performance are becoming limiting factors of Goods-To-Person operations. The popular measure is to increase the picking station quantity. Increasing picking station quantity requires more floor space and conveyors connecting storage and retrieval system and pick stations. As a result, those sometimes will not fit a given space.

Expanding vertically by adding more levels is a common measure but it has a need for extra floor level(s) or incurs extra construction of mezzanine floor. Both of which are realized with an expense of vertical space and investment. Such mezzanine floors are not even possible in some countries due to fire regulations like Japan.

DE 101 36 354 B4 describes a picking method and a picking system for picking, having a container store and associated storage and retrieval machine for removing the containers from and placing them in storage in the container store to and from at least two picking workstations in an order fulfillment level, and having a distribution system for distributing the containers to the individual workstations. A selected container of the container rack is moved via the storage and retrieval machine of a selected storage and retrieval machine, which is operated separately for each workstation, to the picking workstation and that after treatment of the container at the workstation, the container is returned to the container rack via the selected conveyor track. While this allows an efficient supply of articles to the picking station by the dedicated conveyor, it is space consuming.

SUMMARY OF THE INVENTION

The present invention provides an optimized use of space, especially vertical space, in a warehouse.

In accordance with an aspect of the invention, it has been recognized that if each order fulfillment level has at least one further virtual order fulfillment level in which picking stations are arranged at different height from the at least one order fulfillment level, it is possible to use the given vertical space more effectively.

In other words, no change of the building construction by realization of further order fulfilment “floors” or mezzanine constructions are necessary. The idea behind the invention is to use the given order fulfilment level (floor) and amend it by adding a virtual order fulfilment level on the same floor but at a different height, meaning that not only the picking station but also the respective connecting conveyor system is arranged at the different height.

According to an embodiment this can be achieved if the picking stations are arranged at different height from the at least one order fulfillment level creating (defining) the virtual order fulfillment level by vertically raising the picking stations, especially by using raised platforms.

Each order fulfillment level, be it real or virtual, may have dedicated conveyor systems for supply and discharge of articles and/or orders. These conveyor systems may interface with each other. It is also possible to have shared conveyor systems that share common conveyors and interface from the different levels, i.e. heights of the order fulfilment levels. Accordingly, the picking stations arranged in the virtual order fulfillment level(s) may be connected to the product storage for supply with articles from the product storage by at least a second connecting conveyor system arranged at a different height than that of the first connecting conveyor system.

In one preferred embodiment the connecting conveyor system is a connecting conveyor system arranged between the product storage and the order fulfillment area and picking stations therein. This may include but is not limited to the arrangement of the connecting conveyor in the so-called front-zone. It is also possible to arrange said connecting conveyor system so as to be connected to a conveyor loop transporting product from storage to order fulfillment area and/or any further conveying system irrespective of where the products are conveyed from (originate) and transported to (dispatched).

In a preferred embodiment, the connecting conveyor system is a cross-aisle conveyor running the length of the front of the storage segmenting the pre-zone (front-zone).

Alternatively or additionally the connecting conveyor system may connect to a conveyor loop transporting goods from storage to order fulfillment area and/or any conveying system irrespective of where the goods are conveyed from (originate) and transported to (dispatched). The connecting conveyor systems will usually include a main conveyor and interface conveyors branching off this main conveyor connecting/interfacing with the picking stations. The first connecting conveyor system may be arranged below picking stations arranged in the virtual order fulfillment level(s).

Alternatively, the picking stations arranged in both the at least one and virtual order fulfillment levels can be connected to the product storage for supply with articles from the product storage by common vertically movable connecting conveyor system, which e.g. could then interface between dedicated conveyor sections, e.g. using interface conveyors. The respective vertically moveable conveyor section could e.g. be a ramp, that is lowered and raised between the at least two levels or tilted accordingly.

According to a further possibility, the picking stations arranged in the virtual order fulfillment level(s) are connected to the product storage for supply with articles from the product storage by a at least the second connecting conveyor system arranged horizontally offset to that of the first connecting conveyor system. When the connecting conveyor systems are offset horizontally, the second connecting conveyor system and/or the first connecting conveyor system are curved around the respective picking stations in the other level, so that they may still be connected to the respective picking stations directly.

According to aspects of the invention, it is possible that the picking stations are grouped to include a picking station in each level in a horizontally staggered manner (e.g. in longitudinal direction of a respective aisle). In this manner the at least two picking stations of the respective group are horizontally arranged to share airspace, for example by having conveyor sections of a picking station in one level using airspace above a conveyor section of the respective picking station in the other level, so that a compact and efficient use of space is achieved, vertically as well as horizontally. Alternatively (or additionally) in accordance with the invention, each order fulfillment level has at least one further virtual order fulfillment level in which connecting conveyor systems connecting to picking stations are arranged at different height from the at least one order fulfillment level. This also makes use of vertical space more effectively. In other words, the connecting conveyor systems are vertically stacked to use space effectively and at the same time increase throughput and scalability.

According to a further embodiment of the invention, it is also possible that the picking stations connected to different fulfillment levels are horizontally distributed in a longitudinal direction along the main conveyor of the connecting conveyor system (e.g. staggered in cross aisle direction referring to a storage racking opposite). In this manner, using airspace above a conveyor section of the respective picking station in the other level is no longer realized so that a compact and efficient use of space is not achieved. However, as it increases the amount of connecting conveyors (e.g. cross aisle conveyors) whilst quantity of storage aisle and picking station remain unchanged, it has a benefit of significant increase of material flow capacity going through connecting conveyors (e.g. cross aisle conveyors) thus providing more scalability by means of increasing quantity of storage aisles and picking stations without causing traffic congestion on the connecting conveyor system(s). Picking stations are usually, but not limited to, connected to each cross-aisle conveyor level in an alternating manner (lower and upper connecting conveyor alternating in connection to picking stations).

With this concept, both first and second connecting conveyor systems are horizontal and either first or second picking station (alternating) is provided with elevated platform or either or both first and second connecting conveyor systems may include inclined and/or declined interface conveyors and some or all picking stations can be located on the floor level. In case there are more than two connecting conveyor systems and levels (cross aisle conveyors in vertically arranged levels), horizontal, inclined and declined interface conveyors may be used.

A combination of inclined/declined interface conveyors (for connection to the main connecting conveyor) and raised platforms is possible and it is especially useful when two order fulfillment levels are used and there are three connecting conveyor system levels. In other words, it is possible to have different combinations connecting conveyor levels and order fulfillment levels quantity. Usually there will be a 1:1 correspondence between connecting conveyor levels and order fulfillment levels. However, there could also be a 2:1 arrangement or 3:1 arrangement or a 3:2 arrangement. In such arrangements, the picking stations could be connected multiple connecting conveyor levels. The picking stations may be manual picking stations, automated picking stations or fully automated picking stations. If they are fully automated then it is preferred (but not limited to), that the picking stations in the at least one and/or virtual order fulfillment level(s) are robotic stations.

In automated warehouses there are areas between the storage racking and the picking stations in the so-called pre-zone or front zone between the racking and the picking stations in which there are many connecting conveyor systems and across the aisle conveyors such that areas are formed which are not easily to be entered or accessed by human operators. These areas can still be of beneficial use if robotic picking stations are located therein. These do not need to be entered or exited by operators. Therefore, according to the invention, robotic picking stations are located on the product storage side of the connecting cross aisle conveyor, with a dedicated connecting conveyor system in its own virtual order fulfillment level. The robotic picking stations may also be located on the product storage side of the connecting cross aisle conveyor. Then they have a shared connecting conveyor system in the at least one order fulfillment level or virtual order fulfillment level. This allows to make use of non-accessible areas which also exist in the classical area of the picking stations due to the multiple connecting conveyor systems supplying the goods to person stations therein.

In other words, the invention can be characterized, as not only making use of horizontally available space in an order fulfillment level in which picking stations are arranged, but by also making use of the free vertical airspace above (or below) these stations by setting up a virtual order fulfillment level including its own picking stations and connecting conveyors. This is done without installing complete additional flooring or mezzanine levels.

Further features and details of the invention are apparent from the description hereinafter in connection with the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

InFIG.1a schematic perspective view of a picking area1with two picking stations2that are connected to a racking3by conveyors4in an order fulfillment level A is shown. Each picking station2corresponds to an aisle5of the racking3with the racks6neighboring the aisle5in between and is connected to a load carrier vertical conveyor7(e.g. a lift or elevator) arranged within the footprint of each rack6at its front end via the conveyors4. The racks are serviced by ASRS machines not shown, e.g. shuttles, that drop off loads to the vertical conveyors7. Conveyor4cis a connecting conveyor system in the form of a cross aisle conveyor running the length of the front of the racking3across all aisles5and possibly on to a not shown packaging area.

The conveyors4a, b bridge the racking3and the picking stations2, connecting to an inbound product load carrier conveyor8a,band an inbound order load carrier conveyor9a,band a common take away discharge conveyor10. The load carriers themselves can for example be standard containers or trays.

Inbound product load carrier conveyor8has a first conveying section8aleading into the station in extension of the (longitudinal or down) aisle direction and a second conveying section8boriented 90 degrees thereto forming the actual conveying system within the station for presentation of the load carriers with products to pick from to the operator11.

Inbound order load carrier conveyor9has a first inbound conveying section9aleading into the station in extension of the (longitudinal or down) aisle direction and a second conveying section9bwhich is arranged in parallel thereto connected by a right-angle-transfer (RAT)9c.

Product load carrier conveyor section8band load carrier conveyor section9bintersect each other and are forming an operating position13for the operator and intersection14. The intersection can be formed in a wide range of angles, but usually will be in the range between 60 and 120 degrees, preferably 90 degrees.

Common take away discharge conveyor10is arranged in direct extension of order load carrier conveyor section9band starts at the intersection14with product load carrier conveyor section8b.

Each picking station2may include a display and controls12for information of and control by the operator11. The operator may also be guided by other means, like pick-by-light, pick-by-voice and extended/augmented reality etc. The picking station may also not have any such means and picking may be performed based on “paper”.

Product load carrier conveyor section8bas a whole may be tilted towards the operating position13. Another optimization in relation to presentation may be to tilt pick and/or put position. Tilting of the donor position is done by means of tilting conveyor8bitself allowing the product load carrier to be tilted when it is transferred from8ato8b. Tilting of order positions can be done by means of active tilting mechanism e.g. tilted RAT (Right Angle Transfer) and only corresponding put position can be tilted (adaptive tilting) providing operator a distinct indication where the picked items are put to.

The conveyors are controlled by controller15to provide a simultaneous and continuous conveyance flow of product and order carriers through the picking station2on the respective conveyors8,9and10in accordance with the needs for order fulfilment, which in turn is managed by an overall warehouse management system (WMS) interacting and interfaced with an order tracking system. Obviously also the controller is used to control overall material flow within the racking3and5and from there to the picking stations2and3.

In the following schematicFIGS.2-10disclose variations in design and operation of analogous picking stations2according to the invention are described, especially with respect to the use of an additional virtual order fulfilment level(s) B vertically spaced with respect to the order fulfilment level A for better use of space.

InFIGS.2A,2B and3A,3Ban order fulfillment area1000is shown that includes the order fulfilment level A as described above with respect toFIG.1and additionally a virtual order fulfilment level B including further picking stations20and connecting conveyor systems40, all vertically spaced above the order fulfilment level A.

Same as inFIG.1, picking stations2are connected to a racking3by conveyors4in order fulfillment level A and additionally picking stations20are connected to a racking3by conveyors40in virtual order fulfillment level B. As above each picking station corresponds to an aisle5of the racking3with the racks6neighboring the aisle5in between and is connected to a load carrier vertical conveyor7(e.g. a lift or elevator) arranged within the footprint of each rack6at its front end via the conveyors4,40. The racks are serviced by ASRS machines not shown, e.g. shuttles, that drop off loads to the vertical conveyors7. In this respect, virtual order fulfilment level B is more or less a duplicate of order fulfilment level A and arranged above it. To allow this, some additional installations and changes have been implemented which will be described below.

Conveyor40cis a cross aisle conveyor running the length of the front of the racking3across all aisles5and possibly on to a not shown packaging area, arranged above conveyor4c.

The conveyors40a, b bridge the racking3and the picking stations20, connecting to an inbound product load carrier conveyor80a, b and an inbound order load carrier conveyor90a, b and a common take away discharge conveyor100. These are arranged above the respective elements in the level A, using the airspace directly above. The load carriers themselves can for example be standard containers or trays.

To service conveyor system4and40at the same time, especially the conveyors4a, b and40a, b connecting to the racking3, load carrier vertical conveyor or AS/RS7may be used in an embodiment (not shown) having a duplicate load handling platform vertically spaced to align with the two order fulfilment levels A, B so as to be able to discharge and/or receive articles from both levels at the same time.

The picking stations20are manually11or robotically R operated. Two picking stations2,20, one from each order fulfilment level, are also grouped (seeFIG.3showing the respective group of manual picking stations2,20) in close horizontal relationship to create a densely packaged fulfilment area containing many picking stations.

The vertical spacing is realized by having all elements of the virtual order fulfilment level raised by use of uprights, raised platforms etc. The amount of vertical offset is slightly larger than the height of the containers used as load carriers due to but not limited to conveyor height and clearance between conveyor and load carriers.

The operating position130in the picking station40is for example raised by using a platform30. To allow human operators11access to the platform30respectively the operating position130, a section of inbound product load carrier conveyor8acan be raised as best seen inFIGS.2B or3Bor step over can be provided if8ais not raised. Such is not needed for robotically operated stations20R as indicated inFIG.2A.

As seen inFIGS.2and3, virtual order fulfilment level B is independent of order fulfilment level A. Only air space is shared, no conveyor systems. The flow or routing of load carriers is generally the same as described inFIG.1with the respective adaptations to the changes, as indicated inFIG.3. The direction of flow of the load carriers is indicated by the arrows.

The embodiment inFIGS.4A and4Bdiffers from that ofFIGS.2and3in that the picking stations2,20in order fulfilment levels A, B share sections of connecting conveyor system4respectively40. To begin with, the cross-aisle conveyor4crespectively40cis shared (as shown) and in analogy the bridging conveyors4a, b respectively40a, b (not shown) are also shared. In other words, only one connecting conveyor4system is present.

To implement access to both levels, inbound product load carrier conveyor8a, b and80a, b share a common inbound vertically moveable switch50and inbound order load carrier conveyor9a, b, and90a, b, share a common inbound vertically moveable switch52that changes its discharge between the different levels as indicated by the arrow. Likewise, takeaway discharge conveyor10and100share common outbound vertically moveable switch51that changes its merge between the different levels as indicated by the arrow.

The embodiment inFIGS.5A and5Bdiffers from that ofFIG.4in that inbound product load carrier conveyor8a, b and80a, b, inbound order load carrier conveyor9a, b and90a, b as well as take away discharge conveyor10and100are implemented to also interface with the mutual cross aisle conveyor4cby means of fixed ramps. To do so, respective ramps61,62,63,64,65and66are used for inbound supply and discharge of load carriers from and to mutual cross aisle conveyor4crespective connecting conveyor system4.

FIGS.6A and6Bdiffers fromFIG.5in that two cross aisle conveyors4c,40care implemented directly above each other or with some horizontal offset and inbound product load carrier conveyor8ais connected by a ramp61and take away discharge conveyor10by a ramp63too. Declining ramp66connects to inbound order load carrier conveyor9first running parallel to conveyor90and then below, as indicated by the hashed arrow, after reaching the corresponding height of level A. To keep the grouped picking stations compact, the connection from ramp66to inbound conveyor section9ais performed via RATs.

FIGS.7A and7Bshows a further picking station implementation again having two cross aisle conveyors4c,40care implemented directly above each other or with some horizontal offset. The upper level B includes only the connecting conveyor system40for the picking station20and the lower level A includes only the connecting conveyor system4for the picking station2, wherein the connecting conveyors8,9and take away conveyor10snake around the picking station20in the upper level.

The upper virtual order fulfilment level B ofFIG.7Ahas a configuration likeFIGS.2and3in that it has connecting conveyors all in the same level and with straight connection paths to the cross-aisle conveyor40c. In the lower order fulfilment level A ofFIG.7Bhas a configuration similar toFIGS.2and3, however differing therefrom in that the inbound product load carrier conveyor8snakes around operating position130of picking station20of level B as depicted. This allows easy human access without a step over or raised conveyor section (as above).

Inbound order load carrier conveyor9and outbound take away conveyor10in turn also circumvent picking station20and at the same time inbound product load carrier conveyor8.

The embodiment shown inFIG.8is essentially that ofFIG.3wherein the picking station20in order fulfilment level B is robotically operated by robot R. Picking station2in order fulfilment level B may be either manual, robotic or both meaning that a robot R augments the operators11work.

In the further embodiment ofFIG.9, the picking stations2and20in levels A and B are same as inFIG.8. Additionally, a third order fulfilment level C is added below level A which has a robotic picking station200that is connected by a connecting conveyor system400. It is to be understood that level C may also be arranged above level A or B as shown inFIG.10.

This station200is on the opposite side of the cross-aisle conveyors4c,40c,400cwhich are above each other or with some horizontal offset. Therefore, it is positioned between the connecting conveyor systems4,40and400and the racking3, which can be seen inFIG.10. InFIG.10the order fulfilment level B has been omitted for better understanding. However, it is also possible that only levels A and C are implemented together.

Picking station200has its own dedicated conveyors 800 for product load carriers and900for order load carriers as well as a connection to cross aisle conveyor400cby RAT for take away.

The embodiment ofFIG.11is similar to that ofFIG.9in the positioning of picking station200on the opposite side of the cross-aisle conveyors4,40. However, in contrast to before, there is no additional order fulfilment level C but picking station200is arranged within order fulfilment level A and shares its connecting conveyor system4.

FIGS.12-14show embodiments of the invention in which the picking stations are horizontally distributed in a longitudinal direction along the main conveyor of the connecting conveyor system and either connected to each dedicated connecting conveyor system in its own level and/or to connecting conveyor systems of the other levels. InFIG.12an alternative toFIG.3is shown in which the two picking stations do not share air space but are arranged in a horizontally spaced manner along the conveyors4c,40c(seeFIG.12A). Otherwise the installations are the same as inFIG.3. InFIG.13an alternative toFIG.3is shown in which the picking stations2,20in order fulfillment levels A and B again share air space, but there are now three connecting conveyor systems4,40,400(similar toFIG.9). Therefore, the picking stations2,20are same as inFIG.3but now have different interfaces to connecting conveyor systems4,40,400, i.e. conveyors4c,40c,400c, which may be arranged on same or differing levels.

Three examples I, II and III are shown (from top to bottom).

Example I has the same configuration as inFIG.3in such that it only has an interface to conveyors40c,400carranged on same levels and that the lowest conveyor4c(on different not corresponding level) is not connected to the picking stations2,20of example I.

In example II the order fulfillment levels A and B are arranged vertically at heights between those of the connecting conveyor systems4,40,400, i.e. conveyors4c,40c,400c. Additionally, the picking stations2,20are again (as in the previous example I) only connected to two conveyors4c,400c. Due to the height difference the conveyors interfacing picking station2have an incline and those of picking station20have a decline (both from a perspective of conveyor4,400). For example, conveyors8a,80ahave an incline for8aand a decline for80c.

In example III the overall arrangement is the same as in example II, with the difference that the lower two connecting conveyor systems4,40, i.e. conveyors4c,40care interfaced to the picking stations2,20. Therefore, due to the height difference the conveyors8a,80a(and all others, e.g.9,90,10,100etc.) have a decline/incline only. For example, both conveyors8a,80ahave an incline for8aand for80cin the transportation direction from4c,40cto the picking stations2,20.

Of course, all three examples I, II, III ofFIG.13may be combined in same embodiment and it may depend on traffic balance among connecting conveyors4c,40cand400c. For exampleFIG.13shows six picking stations in total and two picking stations are connected to each connecting conveyor of a level achieving a good balance in conveyor traffic.

InFIG.14, there are three connecting conveyor systems4,40,400(similar toFIG.13) in different order fulfilment levels A, B, C but the picking stations2,20,200are arranged in same floor level, as will be explained below. In this embodiment, the order fulfilment levels are defined by the connecting conveyor system. The picking stations2,20,200are each only connected to a single connecting conveyor system4,40,400or respective cross-aisle conveyor4c,40c,400c. Depending on the initial height and arrangement (as best seen inFIG.14B), several variations are possible for implementing the connecting interface conveyors.

Using two connecting conveyor systems, the interface conveyors may be essentially horizontal if the picking station2is on same height (see example I - conveyor8a) or be inclined (towards the picking station) if the picking station 2* is higher than the connecting conveyor (see I - alternative conveyor 8*a). Alternatively, as shown in relation to example III, the connecting interface conveyor (see example III -alternative conveyor 8#a) may be declined, if the height of the picking station 2# is lower.

If the picking station20is arranged in a level between those of conveyors4c,40c(see example II), then the connecting conveyor80amay be declined or inclined (see alternative conveyor80*a - example II).

When all such alternatives are viewed from the side, see example IV, it becomes clear that if the picking station200is on a level with order fulfilment level B of connecting conveyor system40, then the interface conveyors may be inclined if the station is connected to conveyor4c, horizontal if connected to40cor declined if connected to400c.

Obviously all variants and versions described above may be combined as necessary depending on the warehouse needs.