Patent Publication Number: US-2022219904-A1

Title: Transport rack and transport rack docking interface

Description:
CLAIM OF PRIORITY 
     The present application claims priority to U.S. Provisional Patent Application No. 63/136,584 filed on Jan. 12, 2021 entitled “TRANSPORT RACK AND TRANSPORT RACK DOCKING INTERFACE” and U.S. Provisional Patent Application No. 63/250,864 filed on Sep. 30, 2021 entitled “TRANSPORT RACK AND TRANSPORT RACK DOCKING INTERFACE”, which applications are incorporated by reference herein in their entirety. 
    
    
     BACKGROUND 
     An order-fulfillment system for use in supply chains, for example in retail supply chains, may fulfill orders for individual product units, referred to herein as “eaches” (also called “pieces”, “inventory”, “items” or, generally, any articles available for purchase in retail as a purchase unit, etc.), which are typically packaged and shipped by the manufacturer in cases. 
     In a conventional distribution model, the retailer receives pallets of cases at a distribution center (“DC”), the essential role of which is to replenish the inventories in a network of stores by periodically shipping to each store a specific set of cases of products that are needed (have been “ordered”) by that store. In the vast majority of DCs, those orders are fulfilled using a manual case-picking process in which pallets of cases are arrayed in aisles and human operators travel from one product pallet to another to transfer from each the number of cases ordered by the store, placing the selected cases on an order pallet to be shipped to the store. In some DCs, automated case-picking systems are used, the most advanced of which use mobile robots, such as those described in U.S. Pat. No. 8,425,173. Such automated systems do not provide for bulk transport of containers within the distribution center or downstream to retail stores. 
     SUMMARY 
     The present technology, roughly described, relates to an automated storage and retrieval facility comprising a storage structure, mobile robots and mobile racks for use in inventory management, order fulfillment and automation-based capacity planning. In embodiments, a rack or racking system may be used to transport containers, for example, totes. The rack is configured to attach to a load/unload docking station at the storage structure that enables the mobile robots (or “bots”) to load totes onto the rack and/or unload totes from the rack. The racks can further be loaded onto a truck that transports the totes between facilities. 
     In one example, the present technology relates to a docking station for docking a rack for transfer of containers to and from the rack by an autonomous mobile robot in a storage area, the docking station comprising: a port into which the rack may be received for transfer of containers to and from the rack; an engagement mechanism configured to move the rack into a secured position in the port; sensors for sensing when the rack is secured in the port; and a barrier configured to cover the port in the absence of a rack to separate the autonomous mobile robot in the storage area from an area adjacent the docking station where the rack travels, and to uncover the port when the rack is secured in the port to allow transfer of containers to and from the rack by the autonomous mobile robot. 
     In a further example, the present technology relates to a system for transferring containers to and from a storage area to fulfill inventory orders in an automated storage and retrieval facility, the system comprising: a rack configured to carry a plurality of containers and including engagement features configured to be engaged when securing the rack; and a docking station for docking the rack for transfer of the plurality of containers to and from the rack by an autonomous mobile robot in a storage area, the docking station comprising: a port into which the rack may be received for transfer of containers to and from the rack; an engagement mechanism configured to engage the engagement feature of the rack to move the rack into a secured position in the port; sensors for sensing when the rack is secured in the port; and a barrier configured to cover the port in the absence of a rack to separate the autonomous mobile robot in the storage area from an area where rack is moved to and from the port, and to uncover the port when the rack is secured to allow transfer of containers to and from the rack by the autonomous mobile robot. 
     In another example, the present technology relates to a system for fulfilling inventory orders using containers in an automated storage and retrieval facility, the system comprising: a storage area comprising static storage locations for storing the containers; a mobile robot configured to travel on rails adjacent the static storage locations to transfer containers to and from the static storage locations; a rack comprising multiple levels configured to carry the containers, the rack being mobile and configured to move around the automated storage and retrieval facility; and a docking station positioned at the storage area, the docking station configured to receive the rack and register the rack in a position adjacent the rails at the storage area enabling the mobile robot to transfer containers to and from the rack. 
     In a further embodiment, the present technology relates to a system for fulfilling inventory orders using containers in an automated storage and retrieval facility, the system comprising: a storage area comprising first and second static storage locations for storing the containers, the first and second static storage locations each comprising multiple levels for storing containers; an aisle positioned between the first and second static storage locations; a mobile robot configured to travel within the aisle to transfer containers to and from the first and second static storage locations; a rack comprising multiple levels configured to carry the containers, the rack being mobile and configured to move around the automated storage and retrieval facility; and a docking station positioned adjacent the first static storage location, on a side of the first static storage location opposite the aisle, the docking station configured to receive the rack and register the rack in a position adjacent the first static storage location. 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present technology will be described with reference to the following figures. 
         FIG. 1  is a perspective view of a rack according to embodiments of the present technology 
         FIGS. 2A-2C  are perspective views of racks loaded onto a truck or being loaded onto a truck. 
         FIGS. 3A-3I  are perspective views of a storage structure including a docking station for receiving a rack. 
         FIGS. 4A-4B  are perspective views of a rack according to alternative embodiments, and a storage structure including a docking station for receiving the alternative rack. 
         FIGS. 5A-5D  show partial isometric views of a rack including tote locking detail according to embodiments of the present technology. 
         FIGS. 6A-6F  are front, side, top and perspective views of casters for transporting racks according to embodiments of the present technology. 
         FIGS. 7A-7B  are perspective views showing further details of a storage structure and docking station for receiving a rack according to embodiments of the present technology. 
         FIGS. 8A-8B  are perspective views showing a docking station engaged with a rack according to embodiments of the present technology. 
         FIGS. 9A-9C  are views of an alternative docking station including a guide rail and guide roller according to embodiments of the present technology. 
         FIGS. 10A-10L  are views of a docking station configured to receive a rack on a first side and a mobile robot on a second side according to embodiments of the present technology. 
         FIGS. 11A-11B  are perspective views illustrating an autonomous mobile robot for transporting a rack according to embodiments of the present technology. 
         FIGS. 12A-12B  are edge views illustrating a rack positioned at a docking station with a mobile robot including a transfer mechanism for transferring containers between the rack and the mobile robot according to embodiments of the present technology. 
         FIGS. 13A-13B  are edge views illustrating a rack positioned at a docking station adjacent an array of storage locations including a transfer mechanism in the rack and storage locations for transferring containers between the rack and the storage locations according to embodiments of the present technology. 
         FIG. 14  is a perspective view showing racks loaded onto trucks including and aisle between the racks allowing a delivery technician to remove inventory from the racks for home delivery according to embodiments of the present technology. 
         FIG. 15  is a perspective view of a storage area and a stand-alone decant station where containers may be loaded into a rack according to embodiments of the present technology. 
         FIG. 16  is a flowchart for docking and undocking with safety features of  FIGS. 3A-I . 
         FIG. 17  is a flowchart for transporting site to site where each site has automation and storage. 
         FIG. 18  is a flowchart for  FIGS. 12A and 12B . 
         FIG. 19  is a flowchart for  FIG. 13A . 
         FIG. 20  is a flowchart for  FIG. 13B . 
         FIG. 21  is a flowchart for using the truck in  FIG. 14  to deliver grocery orders to customers. 
         FIG. 22  is a flowchart for decant like  FIG. 15 . 
         FIG. 23  is a flowchart for replenishing the automation using a rack and pulling inventory from the store floor. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present technology will be described with reference to the figures, which in general relate to a rack or racking system for use in inventory management, order fulfillment and automation-based capacity planning. More specifically, the technology relates to a rack or racking system used to transport containers, for example, totes, which can attach to a load/unload docking station or fixture that enables bots to load totes onto the rack and/or unload totes from the rack, and further can be loaded onto a truck that transports the totes between facilities. 
     It is understood that the present embodiments may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the invention to those skilled in the art. Indeed, the embodiments are intended to cover alternatives, modifications and equivalents of these embodiments, which are included within the scope and spirit of the invention as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide an understanding of the present embodiments. 
     The terms “top” and “bottom,” “upper” and “lower” and “vertical” and “horizontal” as may be used herein are by way of example and illustrative purposes only and are not meant to limit the description of the embodiments inasmuch as the referenced item can be exchanged in position and orientation. Also, as used herein, the terms “substantially” and/or “about” mean that the specified dimension or parameter may be varied within an acceptable manufacturing tolerance for a given application. In one non-limiting embodiment, the acceptable manufacturing tolerance may be ±0.25%, for example, +/−3 mm tolerance in the Z (vertical) and +/− more in the X down aisle. 
     The racking systems disclosed may be used in conjunction with a robotic picking system(s) and robotics, for example, as disclosed in U.S. Patent Publication Number US2017/0313514 A1 having publication date Nov. 2, 2017 and entitled “Order Fulfillment System” which is incorporated by reference herein in its entirety. Similarly, the racking systems disclosed may be used in conjunction with a robotic picking system(s) and robotics that are deployed in conjunction with retail store formats, for example, as disclosed in U.S. Patent Publication Number US2018/0134492 A1 having publication date May 17, 2018 and entitled “Automated-Service Retail System and Method” which is incorporated by reference herein in its entirety. Further, the racking systems disclosed herein may be used in conjunction with different elements of full or partially automated supply chain systems, for example, as disclosed in the following: U.S. Patent Publication Number US2018/0150793 A1 having publication date May 31, 2018 and entitled “Automated Retail Supply Chain and Inventory Management System”; U.S. Patent Publication Number US2018/0194556 A1 having publication date Jul. 12, 2018 and entitled “Interchangeable Automated Mobile Robots with a Plurality of Operating Modes Configuring a Plurality of Different Robot Task capabilities”; U.S. Patent Publication Number US2018/0247257 A1 having publication date Aug. 30, 2018 and entitled “Inventory Management System and Method” and U.S. Patent Publication Number US2018/0341908 A1 having publication date Nov. 29, 2018 and entitled “Fully Automated Self Service Store”, all of which are incorporated by reference herein in their entirety. Further, the racking systems disclosed herein may be used in conjunction with different elements of racking systems, for example as disclosed in U.S. Patent Application No. 63/013,504 entitled Transport Rack Cartridge (TRC) having a filing date Apr. 21, 2020 and U.S. Patent Publication Number US2018/0194556 A1 having publication date Jul. 12, 2018 and entitled “Interchangeable Automated Mobile Robots with a Plurality of Operating Modes Configuring a Plurality of Different Robot Task capabilities” all of which are incorporated by reference herein in their entirety. 
     The racking systems disclosed may be utilized in the foregoing examples and further by way of non-limiting example in applications such as summarized in Table 1: 
     
       
         
           
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 CLASSIFICATION 
                 IN 
                 OUT 
               
               
                   
               
             
            
               
                 DC (Distribution 
                 Pallets 
                 Rainbow Pallets 
               
               
                 Center) 
               
               
                 RDC (Regional 
                 Pallets, Rainbow 
                 Single &amp; Mixed SKU 
               
               
                 Distribution Center) 
                 Pallets, Empty Totes 
                 Product Totes 
               
               
                 Darkstore 
                 Single &amp; Mixed SKU 
                 Order Totes, Empty 
               
               
                   
                 Product Totes, Empty 
                 Totes 
               
               
                   
                 Totes 
               
               
                 RSD (Remote Storage 
                 Order Totes 
                 Empty Totes 
               
               
                 Dispense) 
               
               
                 SPSD (Store Picking &amp; 
                 Single &amp; Mixed SKU 
                 Order Totes, Empty 
               
               
                 Storage Dispense) 
                 Product Totes, Empty 
                 Totes 
               
               
                   
                 Order Totes 
               
               
                 SSD (Store Storage 
                 Closed System 
                 Closed System 
               
               
                 and Dispense) 
               
               
                   
               
            
           
         
       
     
     A classification example that may utilize the racking systems disclosed herein may be a retail or other Distribution Center (DC). A Distribution Center (DC) may distribute goods to retail stores or Regional Distribution Centers (RDC) where the distribution center may be one or more warehouse(s) that receives pallets that may contain common cases of goods and ships “rainbow pallets” that may contain layers or mixed cases of goods for shipment to Regional Distribution Centers. The disclosed rack system may be utilized to store and ship the goods from multiple pallets or in the absence of pallets may be utilized to store and ship racks of cases, or totes containing the contents transferred from the cases. 
     Another classification example that may utilize the racking systems disclosed herein may be a Regional Distribution Centers (RDC) that distributes goods to retail stores. Here, the regional distribution center may be one or more warehouse(s) that receives pallets of common cases, rainbow pallets of mixed cases, and/or empty totes and ships single &amp; mixed SKU Product Totes to retail stores. 
     Another classification example that may utilize the racking systems disclosed herein may be a Darkstore that distributes goods to customers. Here, the Darkstore may be one or more warehouse(s) that receives Single &amp; Mixed SKU Product Totes or Empty Product totes and ships or dispenses Order Totes to customers or Empty Order Totes to be replenished. 
     Another classification example that may utilize the racking systems disclosed herein may be a Remote Storage Dispense facility (RSD) that distributes goods to customers. An RSD facility may be used primarily where the facility uses totes primarily for storage and dispense only. Here, the Remote Storage Dispense may be one or more location(s) that receives Order Totes and ships or dispenses Orders customers or Empty Totes to be replenished. 
     Another classification example that may utilize the racking systems disclosed herein may be a Store Picking &amp; Storage Dispense facility (SPSD) that distributes goods to customers. Here, the Store Picking &amp; Storage Dispense facility may be one or more location(s) that receives Single &amp; Mixed SKU Product Totes or Empty Order Totes and ships or dispenses Order Totes to customers or Empty Totes to be replenished. 
     Another classification example that may utilize the racking systems disclosed herein may be a Store Storage and Dispense facility (SSD). Although this type of facility is a closed system, the racking system may be utilized, for example, for importing additional order totes remotely as supplemental to floor picking with order or product totes being received and empty totes shipped to be replenished. 
     Each of the exemplary instances above are provided as an array of possible applications of the racking systems disclosed herein where numerous applications may be anticipated. For example, the racking system described may be used in ambient picking systems for shipping, receiving and replenishment. Similarly. The racking systems described may be used with ambient picking systems but also with chilled or frozen picking systems. Accordingly, and by way of example, anything within or downstream of a distribution center may utilize the racking systems disclosed to manage inventory for industrial or commercial product or merchandise with cases, totes, sub-totes or otherwise within a given supply chain or operation. Another example is where general merchandise orders might be shipped on tracks to a store to be integrated with customers&#39; grocery orders. 
     Much of the labor requirements to operate a picking system stems from the need to pull van delivery orders, place them in a rack and load them onto the truck. The disclosed racking system is provided to reduce the amount of labor required to do this task and improve the overall system efficiency. 
     Racks may be used to efficiently transport totes between storage and picking systems located in different locations. As will be described, racks dock directly with storage structures where bots can directly pick and place totes from and to the rack. By way of example, a rack docked to a storage structure may be filled with totes containing customer orders. Once all shelves of the rack have been populated with totes, the rack may be undocked from the storage system and transported either manually, or by autonomous mobile robot (AMR) into a transport truck, for example, a 13′ commercial box truck. The box truck transports the rack to a RSD where it is manually unloaded by associates. The order totes will either be inducted into the system or manually delivered to customers. If inducted, the order totes will be transported to customer portals via bots, where customers retrieve their orders. Then, the bots retrieve the now empty totes and place them back into the rack. Once a rack contains all empty totes, it is undocked from the RSD and transported either manually or with an AMR back to the box truck for transport back to an Automated Picking, Storage &amp; Dispense (APSD) system. This closed loop operation enables efficient and fully automated transport of totes between facilities where measures for human safety are considered and described. Efficiency may further be gained by how the bots load and unload the rack with each cycle. Initially, one tote is removed from the rack to create a vacancy. After this cycle, each bot loads one tote into the rack at the vacant position, and retrieves an adjacent tote, thereby creating a vacancy for the subsequent bot cycle. 
     Referring now to  FIG. 1 , there is shown an isometric view of rack  110 . Rack  110  has tote support structure  112  holding totes  114  where totes  114  may also have sub-totes  116  for carrying goods. Tote support structures may also be referred to as “shelf structures” or “shelf modules” or otherwise as alternatives to “tote supports”. Rack  110  is shown with 5 totes  114  in each row of totes; in alternate aspects more or less totes may be provided. Vertical supports  118  may be provided in rack  110  supporting four rows of totes each respectively. In the embodiment shown, four rows each are shown but in alternate aspects, more or less rows may be provided. For example, racks used for picking goods from the store floor may be 3 rows high to permit workers to see above the racks. Casters  122  may be provided to support rack  110  and allow rack  110  to be freely moved around on a surface  126 , for example on a surface that allows rack  110  to be coupled to a structure that allows Bots to access racks  110  or on a surface that may be a loading dock for trucks, containers or otherwise. As a further alternative, casters  122  may allow free movement on a surface that is in the interior of a truck box or container where rack  110  may be restrained to the interior of the truck box or container for transport or shipment to another facility, for example, retail facility, distribution center or otherwise as described. Casters  122  may be conventional rotating and locking casters or simply conventional casters; in alternate aspects, casters  122  may be spherical wheels to make the heavy rack easier to maneuver into position. 
     Rack  110  may have guide features  130 , for example holes in the rack structure that correspond to mating pins in the mating automation where the holes may provide location and a go/no-go feature with respect to the mating pins. Here, docking features are provided that secure the rack to the storage structure when docked as will be described. Rack  110  may have interlock or identification features such as feature  132  on one side or two opposed or adjacent sides of rack  110 . Feature  132  may be a RFID tag or other identification feature or location indicia that may be provided to detect identification of the rack and or location of the rack with respect to a mating interface such that the rack may be determined to be in position, for example, to allow totes to be removed from or inserted into the rack  110  by Bots. Here RFID or other suitable tags  132  may provide for safety interlocking of the rack  110  with respect to mating or docking structure. Handles  136  may be provided to allow an operator to ergonomically move rack  110  from location to location. Although rack  110  may have any suitable size, representative dimensions may have totes at 415 mm horizontal tote pitch and 400 mm vertical tote pitch with 167 mm from the floor surface to the bottom of level 1 of the totes. The overall size of the rack may have a width of 2190 mm or 86.22″ that fits within a 88.25″ box truck door width as will be shown; a height of 1667 mm or 65.63″ fits within a 71.25″ box truck door height as will be shown; and 590 mm depth where 600 mm totes may protrude 22 mm and with a 12 mm maximum rear panel dimension. Alternately, any suitable dimension may be used, for example, tote guides overhang of 1.6 inches. Although racks  110  will be shown inserted depth-wise into the box of a truck, racks  110  may be oriented in any suitable arrangement within the box of a truck, shipping container or otherwise. 
     Referring now to  FIGS. 2A-2C , there is shown isometric view of truck  210 . Truck  210  is shown having box  214  and liftgate  216 . In  FIG. 2A , truck  210  is shown as a 13′ Box truck fully loaded with racks  110 . In alternate aspects a different sized truck loaded with more or less racks in alternate orientations may be provided. By way of example, truck  210  is shown with 6 racks  110  each 5 totes wide and 4 totes high for a total of 120 totes in truck  210  when loaded. Truck  110  may be provided with features not shown, for example, environmental control features such as heating or cooling features and docking features that allow racks  110  to be secured within box  214 . In  FIG. 2B , truck  210  is shown with one of the racks  110  withdrawn from box  214  onto liftgate  216  which is shown in an up position. Here, rack  110  is shown on liftgate  216  where liftgate  216  may have for example an 1800 lb. capacity with rack  110  having less than a 1200 lb. load. In  FIG. 2C , truck  210  is shown with one of the racks  110  withdrawn from box  214  onto liftgate  216  which is shown in a down position where rack  110  may be removed from the truck  210 . 
     Referring now to  FIGS. 3A-3I , there are shown isometric views of storage structure  230 . Storage structure  230  has static storage locations  234 , rack docking station  236  and bot support rails  238  that are provided to support autonomous bot  240  such that autonomous bot  240  may access any tote for removal or placement with respect to static storage locations  234  and rack  110  when docked. Operator  244  is shown moving rack  110  into the docking station  236 . As can be seen in  FIGS. 11A and 11B , in alternate aspects, autonomous mobile robot (AMR)  246  may be provided to move rack  110  from location to location. Rack  110  may have a bottom plate used for lifting, or propelling on its casters by the AMR where the bottom plate may have locking features to secure rack  110  to the AMR and where the bottom plate may further be used as ballast to prevent tipping of rack  110  during transport or movement. Alternately, extensions (wheelie bars) may extend from the rack and nest as shown with respect to the casters. As seen in  FIGS. 3A and 3H , docking station  236  has housing  252  which is shown with lead in edges for guiding rack  110  into docking station  236 . Further docking station  236  has RFID Safety Reader(s)  256  that correspond to safety and/or id tags on rack  110 . Further docking station  236  has safety door  260  (may be a roll up door or other suitable door) that prevents the operator from being able to access the safety zone in which bot  240  is operating. Here, door  260  provides a safety features to prevent human contact with exposed bot traffic within structure  230 . The safety door may also cooperate with the mechanism that engages rack with the docking station where the safety door may be used to seat totes that have slid out during transport with the rack being drawn toward the docking station such that the totes are driven into the rack as the rack is drawn toward the door. The rack may then be pushed away from the docking station to provide clearance between the totes in the racks allowing the door to open such that the rack can then be fully engaged with the docking station. Here, the door may be used to reseat totes into the rack prior to docking and presenting to the bots. As an alternative to the door, a safety rated light curtain may be provided that prevents humans from accessing the bots moving within the rails. When the rack is inserted sufficient to satisfy the RFID safety sensors  256 , the light curtain can be disabled to allow the rack to be fully inserted into the position where bots pick and place totes. In the event a human interrupts the light curtain without the rack in place, an emergency-stop is activated to prevent the motion of all bots within the system or local to the docking module. An example of a suitable safety system in which safety door  260  may be utilized to prevent operator injury is disclosed in U.S. Patent Publication No. US2019/0176323 entitled “Configurable Service Isolation Zone for Service of Equipment Employing mobile Robots” published Jun. 13, 2019 and incorporated by reference herein in its entirety. 
     Further docking station  236  has side latches  264  and pins  266  where side latches  264  (both sides) need to be engaged by the rack  110  in order to safely allow the safety door  260  to open safely and where side latches  264  further pull the rack  110  into engagement with pins  266  where the pins  266  (both sides) need to mate with corresponding holes in rack  110  before bot  240  can reliably access the totes in rack  110 . The pin hole interface may serve as an interlock that ensures the rack is adequately positioned to promote reliable transfers of the totes by the bots. Here, side latches  264  lock the rack in place when connected to the storage structure. RFID safety readers  256  or other sensing of rack  110  may be provided to serve as verification that rack  110  is in position, for example to allow door  260  to safely open.  FIG. 3A  shows rack  110  during loading with rack  110  being transported by operator  244  and with the safety door  260  closed.  FIG. 3B  shows rack  110  during loading with rack  110  being transported by operator  244  with rack  110  engaging the lead in of frame  252  of docking station  236  and with the safety door  260  closed.  FIG. 3C  shows rack  110  during loading with rack  110  being inserted by operator  244  with rack  110  being inserted into docking station  236  and with the safety door  260  closed. Here, the safety RFID is not activated if rack  110  is not fully inserted into docking station  236  where door  260  has an additional purpose to ensure totes that may have slipped or slid out of rack  110  are fully seated in rack  110  before opening door  260 . In addition to the door serving to ensure totes are fully seated in the rack, through-beam sensors or cameras may be used to identify totes protruding from the rack. In the event totes are protruding, the docking mechanism may advance the rack against the door while still closed to reseat the totes. Once the rack has been advanced to reseat the totes, the rack may be reversed to a position to where sensors may optionally confirm the totes are seated within the rack prior to opening the door and advancing the rack into its fully docked positions where bots pick the totes.  FIG. 3D  shows rack  110  inserted into docking station  236  with the safety door  260  safely opening.  FIGS. 3E and 3F  show rack  110  fully docked and locked in docking station  236  where the side latches  264  pull rack  110  onto the Go/No-Go pins  266  and where rack  110  is now fully docked, locked and accessible by bots  240 .  FIG. 3G  shows rack  110  fully docked and locked in docking station  236  where bot  240  can now unload tote  272 .  FIG. 3I  shows an opposing side of structure  230  where an additional docking station  236  may oppose the station as described where bot  240  can access totes on either side of structure  230 . 
     In embodiments including an upwardly opening door  260 , the door may open to its fullest extent when the sensors confirm the rack is in its fully docked position. Alternatively, the door may raise upward to height just above the height of the rack  110 . Additional sensors may be provided to sense the height of the rack  110 , or this information may be read from feature  132 . As seen for example in  FIG. 3I , a pair of docking stations  236  may be provided facing each other on opposite sides of an aisle in which BOTs  240  travel. The docking stations  236  need not be provided in opposed pairs in further embodiments. 
     Referring now to  FIG. 4A  there is shown an isometric view of rack  110 ′. Rack  110 ′ may have features similar to rack  110  except rack  110 ′ has 3 rows of totes instead of 4 rows of totes as shown with rack  110 . Further rack  110 ′ has cover  276  which prevents contaminants or debris from falling into the totes stored within rack  110 ′, for example during transport and prevents humans from accessing the top-level totes when interacting with the bots. Referring also to  FIG. 4B , there is shown structure  230  where rack  110 ′ is docked to docking station  236 . Of note is where the RFID may be a unique identifier for each rack and may track features of each rack, for example, the number of shelves in each rack such that door  260  is only opened sufficiently to allow bot  240  to safely access the shelves of rack  110 ′ but not opening so far as needed for access to the 4th shelf of rack  110  exposing a safety hazard. Similarly a back (not shown) may enclose the exposed side of the rack to prevent humans from reaching into the space while bots pick and place totes. Here, docking station  236  is shown able to access racks of multiple heights without reconfiguring the hardware. 
     Referring now to  FIGS. 5A-5D , there are shown partial isometric views of rack  110  showing tote locking detail. Totes  114  are shown nested on shelves  112  where shelves  112  are shown having a rotating retention feature  184 . Each tote  114  has an individual retainer  184  that is rotated out of place as seen in  FIG. 5A  when the rack  110  is docked allowing the totes to be freely removed and replaced by bots or otherwise. Similarly, individual retainer  184  that is rotated in place as seen in  FIG. 5B  when the rack  110  is un-docked retaining the totes and preventing the totes from being removed during rack  110  transport or otherwise.  FIG. 5C  shows linkage  186  that engages or disengages the individual retainers  184  with respect to the totes in unison as the rack  110  is being undocked or docked.  FIG. 5D  shows the retainers engaged preventing the totes from being removed from rack  110 . Rack  110  is also shown having features  190 ,  192  (tote guides) that guide totes into the rack and secure their position during transport. Features  190 ,  192  are shown having flags  194  that may be white or any suitable fine positioning flags. Here, cams or caroming surfaces/features may be activated to push tote locks up so the totes are retained during transit where stops may be provided on the rear of the tote guides to prevent removal at any time. In an example embodiment, totes are retained into their rack position by solely detent bumps on the horizontal surfaces of the tote guides. 
     Referring now to  FIGS. 6A-6C  there are shown partial isometric side and rear views of rack  210 . Rack  210  has front  214  and rear  216  casters that are offset such that as racks are butted together, the casters envelopes can nest within each other as seen in  FIGS. 6D-6F . Here, the distance between the front casters is smaller than the distance between the rear casters such that they can engage separate ramps when docking as will be described (and/or may be utilized for nesting purposes). Guide  218  is shown as an exemplary guide that allows a stationary pin to be provided, for example, on a docking station to ensure the rack is properly positioned. 
     Referring now to  FIGS. 7A-7B , there are shown isometric views of rack  210  and docking station  232 . Docking station  232  has outer ramps  234  that engage with rear casters  216  and inner ramps  236  that engage with casters  214  such that as the rack  210  is docked the ramps cooperate with the casters such that the attitude of the rack remains horizontal as the rack is lifted from the floor. Ramps are utilized in the event the floor is uneven or to compensate for differing floor heights. Pin  238  may be provided to guide rack  210  in position and docking engagement drives may be provided to dock rack  210  to docking station  232 . Referring also to  FIGS. 8A and 8B  there are shown partial isometric views of docking station  232  docking rack  210 . Docking station  232  has docking drive  240  having rotating drive arms  245  on opposing sides of rack  210  that have rollers that engage slots  248  of rack  210  on opposing ends of rack  210 . As rack  210  is moved into a docking position with docking station  232 , arms  245  are lowered to allow rack  210  to clear arms  245 . To dock, arms  245  rotate up as seen in  FIG. 8A  engaging slots  248 . Arms  245  continue to rotate as seen in  FIG. 8B  pulling rack  210  up on the ramps and docking rack  210 . In alternate aspects, any suitable docking mechanism may be provided. 
     Referring now to  FIGS. 9A-9C , as an alternative to guide  218  and pin  238 , a guide rail  260  and guide roller  262  may be provided with docking station and rack respectively. Guide roller  262  is not in communication with the floor of the facility when the rack is being transported, thereby eliminating the effect of transportation wear on the docking accuracy of the rack to the docking station. In alternate aspects, any suitable guiding mechanism may be provided such that when the rack is docked, it is in position to allow reliable tote transfer. 
     Referring now to  FIGS. 10A-10L , there is shown docking station  320 , rack  310  and Bot  240 . In the figures, the storage structure is not shown where Bot  240  is supported on rails where rails (vertically or opposing for example) are also not shown for clarity. Further features, such as the safety door are not shown for clarity. Docking station  320  is shown illustrating an alternate docking drive mechanism  360 . Docking mechanism  360  has drive motor  366  which is coupled to right angle gear or drive box  368  the output of which rotates shaft  370 . As seen in  FIG. 10J , shaft  370  extends to opposing sides of the docking station to drive arms  384  that engage features of the rack to dock and undock the rack as will be described in greater detail. On each side of the docking station, shaft  370  is coupled to sprockets or timing pulleys  374  which drive sprocket or timing pulleys  376  via chains or timing belts  380 . Sprocket or timing pulleys  376  are coupled to rotating arms  384  which are utilized to dock and undock rack  310 . Each arm  384  has a roller  388  that engages a slot  392  of opposing u-channels  394  of rack  310  where the rack  310  can engage and disengage the docking station freely as shown in  FIG. 10E  where the roller moves through the slot  392  in u channel  394 . When the rack  310  is positioned such that the roller  388  passes through the slot  392  as shown in  FIG. 10E , the rack is positioned to be engaged where rotation of the arm  384  causes the roller to pass from the slot into the u channel drawing the rack  310  into locking engagement with the docking station  320 . In the exemplary embodiment, bearings  402  may be provided to constrain components such as shafts, sprockets and rotating arms. Further, limit switches and or position sensors may be provided to detect proper positioning of the rack and associated engagement features. In the manner described, rotation of drive motor  366  rotates arms  384  in unison to draw rack  310  into or out of engagement with docking station  320  as a function of rotation direction and position. In the disclosed, 4 arms are provided; 2 on each side of the rack  310 ; in alternate aspects more or less may be provided, for example 2 on one side and 1 on the other. 
       FIGS. 12A and 12B  show rack  310  at a docking station  320  (shown schematically in  FIGS. 12A-13B ). Once positioned at docking station  320 , a bot  240  may exchange totes  272  between the rack  310  and storage locations  234  of storage structure  230 . In particular, the rack  310  may be supported on AMR  246 , and AMR  246  may move the rack  310  into docking position with docking station  320 .  FIG. 12A  shows a tote  272 A on bot  240  whereas  FIG. 12B  shows the tote  272 A having been moved into the rack  310 , with another tote  272 B on the bot  240 . Totes  272  may additionally or alternatively be moved from rack  310  to storage locations  234 , or from one position in rack  310  to another position in rack  310 . The bot  240  is provided with a shuttle or tote transfer mechanism  766 , for example as disclosed in U.S. Patent Publication No. US 2017/0313514 published Nov. 2, 2017 which is incorporated by reference herein in its entirety. Here, the shuttle or tote transfer mechanism  766  on bot  240  may selectively place totes to AGV/PGV  756  for removal from ASRS  762  or pick totes from AGV/PGV  756  for induction into ASRS  762 .  FIGS. 15A and 15B  show an example of a synchronous handoff between AGV/PGV  756  and bot  760  where timing and location of the two for transfer need to be synchronously handled. 
     Referring now to  FIGS. 13A and 13B , there is shown an end view of a rack  310  at a docking station  320 . Once positioned at docking station  320 , a bot  240  may exchange totes  272  between the rack  310  and storage locations  234  of storage structure  230 . In this embodiment, each storage location for storing totes  272  within rack  310  may include a transfer mechanism integrated into the storage location. The transfer mechanism may for example be a shuttle or tote transfer mechanism  766 . Thus, once AMR  246  docks the rack  310  to the docking station  320 , the transfer mechanisms within the rack  310  may transfer totes  272  from rack  310  to the array of storage locations  234  in storage structure  230 A immediately adjacent to the storage rack  310 , or the transfer mechanisms within rack  310  may transfer totes from the storage locations  234  in storage structure  230 A into the rack  310 . Storage locations including a transfer mechanism may be considered “active,” where storage locations not including a transfer mechanism may be considered “passive.” Thus, in the embodiment of  FIG. 13A , the storage locations in rack  310  are active, the array of storage locations  234  in storage structure  230 A are passive, the bot  240  is active, and the array of storage locations in storage structure  230 B are passive. Using this structure, totes  272  may be moved between any of the rack  310 , the storage locations  234  in storage structure  230 A and the storage locations  234  in storage structure  230 B. In the examples of  FIGS. 13A and 13B , it is conceivable that a transfer mechanism be provided that transfers all totes  272  from rack  310  to the storage locations  234  in storage structure  230 A at the same time, or vise-versa (from storage structure  230 A to rack  310  at the same time). In the example of  FIG. 13A , the transfer mechanism  766  on the bot is unable to reach storage locations within the rack  310 . Thus, providing the storage locations within the rack  310  with active transfer mechanisms allows automated transfer to and from the rack  310 . 
       FIG. 13B  shows a similar embodiment to  FIG. 13A , but in this embodiment, transfer mechanisms such as the shuttle or tote transfer mechanisms  766  may be omitted from the storage locations in rack  310 , and are instead incorporated into the storage locations  234  of storage structure  230 A. Thus, in the embodiment of  FIG. 13B , the storage locations in rack  310  are passive, the array of storage locations  234  in storage structure  230 A are active, the bot  240  is active, and the array of storage locations in storage structure  230 B are passive. Using this structure, totes  272  may be moved between any of the rack  310 , the storage locations  234  in storage structure  230 A and the storage locations  234  in storage structure  230 B.  FIGS. 13A and 13B  show examples of an asynchronous handoff between rack  310 , storage locations  234  in storage structures  230 A,  230 B and bot  240 , where timing and location of the rack  310  and storage structures  230 A,  230 B for transfer need not be synchronously handled. In the examples of  FIGS. 13A and 13B , it is conceivable that a transfer mechanism be provided that transfers all totes  272  from rack  310  to the storage locations  234  in storage structure  230 A at the same time, or vise-versa (from storage structure  230 A to rack  310  at the same time). That transfer mechanism can be all shuttle or tote transfer mechanisms in the rack or storage structure  230 A moving totes at the same time, or some other mass-transfer mechanism. 
     There may be a variety of applications for the rack  310  of the present technology. In one example, the rack  310  may be used in a “hub-and-spoke” distribution system, where an automated distribution center (the hub) may load racks  310  with totes for shipment out to a number of retails stores (the spokes) which may or may not have automation. Racks  310  may be sent to stores with automation, or other distribution centers having automation. In such examples, upon arrival at the automated store or facility, the racks may be assimilated into the storage system by docking at a docking station  320  as described above. Racks  310  travelling between automated facilities may include order or product totes (totes containing fulfilled orders, or inventory for fulfilling orders). 
     In a further example, racks may be loaded with orders at a distribution center for home delivery. In such an example, racks  310  may be loaded onto a truck  210  as shown in  FIG. 14 . Totes  272  with orders for home delivery may be loaded into racks  310  from the storage structure  230  while the racks  310  are at the docking station  320 , for example according to any of the embodiments described above. Thereafter, the racks  310  may be brought to trucks  210  (either on casters or by AMRs  246 ) and loaded onto trucks  210 . The racks may be loaded along the edges of trucks  210  to leave an aisle  315  within the trucks. Each of the racks may be secured to the truck for transport using straps  317  securing the rack to the floor and/or walls of the truck where straps  317  may be applied horizontally, vertically or otherwise. Alternately any suitable method of securing the racks to the truck may be used. Thus, upon arriving at a home location, a delivery person can walk within aisle  315  and retrieve one or more sub-totes or bags within the appropriate tote  272 , and deliver the items to that home location. The orders within totes  272  may be intelligently loaded into the truck  210 , taking into consideration a route the driver will take to make the home deliveries so that the driver can efficiently retrieve orders from totes  272  while make the home deliveries. 
     A further application of racks  310  are for use at stand-alone load or unload stations within an automated facility. For example,  FIG. 15  shows an example of a rack  310  at a stand-alone decant station  350 . Inventory may be received at decant station  350 , for example on pallets  352 . Thereafter, any packaging may be removed from the inventory, and the inventory transferred to totes  272  at station  350 . The inventory may be unpackaged and transferred into the totes  272  manually or by automated processes. Thereafter, the totes  272  may be loaded into rack  310 , and the totes  272  in rack  310  may be assimilated into the storage location  230  at docking station  320  according to embodiments described above. Stand-alone stations such as decant station  350  may be advantageous in that you can have multiple such stand-alone stations to load multiple racks  310  outside of the critical path and operation of the automated storage and retrieval system (i.e., bots  240  interacting with storage structure  230 ). The racks can also enable off-line bagging of totes that are loaded onto racks, permitting the induction of bagged totes to be performed asynchronously between the humans and bots. 
     In embodiments described above, the AMR  246  is used to transport racks  310  to trucks, which then depart for delivery of the racks. In further embodiments, the AMR  246  itself may depart the automated order facility and deliver racks  310 , or individual totes  272 , to retail stores, to customers&#39; homes and/or to other locations. 
       FIG. 16  is a flowchart for docking and undocking with safety features of  FIGS. 3A-I . In step  1600 , a rack  110  containing totes is transported to the docking station  236 . The rack  110  may be manually guided into the docking station, or guided by an AMR  246  ( 1602 ). When the rack is inserted sufficient to satisfy the RFID safety sensors  256  ( 1604 ), the light curtain can be disabled to allow the rack to be fully inserted into the position where bots pick and place totes. In the event a human interrupts the light curtain without the rack in place in step  1604 , an emergency-stop is activated to prevent the motion of all bots within the system or local to the docking module. In step  1606 , the docking station  236  verifies that the rack is properly positioned at the docking station. Docking station  236  has side latches  264  and pins  266  where side latches  264  (both sides) need to be engaged by the rack  110 . Once the rack properly engages the latches  264 , the safety door  260  may open safely ( 1610 ). Thereafter, bots  240  traveling within bot support rails  238  may access tote storage locations within rack  110  ( 1612 ). 
       FIG. 17  is a flowchart for transporting site to site where each site has automation and storage. In step  1700 , a rack  110  may be docked to a docking station  236  of a first storage structure  230  (storage structure A), and bots may transfer totes to and/or from rack  110  ( 1702 ). When tote transfer is complete, rack  110  may undock from docking station  236  either manually or automatedly positioned on an AMR  246  ( 1704 ), and the rack  110  may be manually or automatedly transported to a vehicle ( 1706 ) such as a truck  210  shown in  FIGS. 2A-2C . The rack  110  may be docked to the vehicle in step  1708  by itself or along with one or more of the racks  110 . The vehicle may include docking features that allow racks  110  to be secured within the vehicle. The one or more racks  110  are then transported by the vehicle to an alternate site ( 1710 ), whereupon the one or more racks  110  are undocked from the vehicle ( 1712 ) and transported away from the vehicle into the new site ( 1714 ). In step  1716 , a rack  110  may be docked to a docking station  236  of a storage structure  230  at the new site (storage structure B), and bots may transfer totes to and/or from rack  110  at storage structure B ( 1718 ). 
       FIG. 18  is a flowchart for  FIGS. 12A and 12B . In step  1800 , an AMR  246  may move to a rack  310  (or the rack  310  may be moved to the AMR) and the AMR  246  may engage and support the rack  310  ( 1802 ). The AMR  246  then transports the rack  310  to a docking station  236  ( 1804 ), and the AMR  246  positions the rack  310  for docking at the docking station  236  and storage structure  230  ( 1806 ). Thereafter, bots  240  may exchange totes  272  between the rack  310  and storage locations  234  of storage structure  230  ( 1808 ). As noted above, a bot  240  may include a tote transfer mechanism  766  for transferring totes  272  between rack  310  and the storage locations  234 . The AMR  246  may either stay at the rack  310  during step  1808 , or the AMR may be dispatched for other work while the rack is being loaded. Once transfer of totes  272  to/from rack  310  is completed, the AMR  246  undocks the rack  310  from the storage structure  230  ( 1812 ) and the AMR  246  transports the rack  310  to a new destination ( 1814 ). The AMR  246  may they stay engaged, or the AMR  246  may disengage from the rack  310  upon arrival at the new destination ( 1816 ). 
       FIG. 19  is a flowchart for  FIG. 13A . In step  1900 , an AMR  246  may move to a rack  310  (or the rack  310  may be moved to the AMR) and the AMR  246  may engage and support the rack  310  ( 1902 ). The AMR  246  then transports the rack  310  to a docking station  236  ( 1904 ), and the AMR  246  positions the rack  310  for docking at the docking station  236  and storage structure  230  ( 1906 ). Thereafter, bots  240  may exchange totes  272  between the rack  310  and storage locations  234  of storage structure  230  ( 1908 ,  1910 ,  1912 ). As noted above, each storage location for storing totes  272  within rack  310  in the embodiment of  FIG. 13A  may include a transfer mechanism integrated into the storage location. Thus, in step  1908 , the transfer mechanisms within the rack  310  may transfer totes  272  from rack  310  to the passive storage locations  234  in storage structure  230 A, in step  1910 , the transfer mechanisms within the rack  310  may transfer totes  272  between passive storage locations  234 , or in step  1912 , the transfer mechanisms within rack  310  may transfer totes from the storage locations  234  in storage structure  230 A into the rack  310 . The AMR  246  may either stay at the rack  310  during step  1908 / 1910 / 1912 , or the AMR may be dispatched for other work while the rack is being loaded. Once transfer of totes  272  to/from rack  310  is completed, the AMR  246  undocks the rack  310  from the storage structure  230  ( 1914 ) and the AMR  246  transports the rack  310  to a new destination ( 1916 ). The AMR  246  may they stay engaged, or the AMR  246  may disengage from the rack  310  upon arrival at the new destination ( 1918 ). 
       FIG. 20  is a flowchart for  FIG. 13B . In step  2000 , an AMR  246  may move to a rack  310  (or the rack  310  may be moved to the AMR) and the AMR  246  may engage and support the rack  310  ( 2002 ). The AMR  246  then transports the rack  310  to a docking station  236  ( 2004 ), and the AMR  246  positions the rack  310  for docking at the docking station  236  and storage structure  230  ( 2006 ). Thereafter, bots  240  may exchange totes  272  between the rack  310  and storage locations  234  of storage structure  230  ( 2008 ,  2010 ,  2012 ). As noted above, in the embodiment of  FIG. 13B , the transfer mechanisms may be omitted from the storage locations in rack  310 , and may instead be incorporated into the storage locations  234  of storage structure  230 A. Thus, in step  2008 , the transfer mechanisms within the storage structure  230 A may transfer totes  272  from rack  310  to the active storage locations  234  in storage structure  230 A, in step  2010 , the transfer mechanisms within the storage structure  230 A may transfer totes  272  around within the storage structure  230 A and/or  230 B, or in step  2012 , the transfer mechanisms within storage structure  230 A may transfer totes from the active storage locations  234  in storage structure  230 A into the rack  310 . The AMR  246  may either stay at the rack  310  during steps  2008 / 2010 / 2012 , or the AMR may be dispatched for other work while the rack is being loaded. Once transfer of totes  272  to/from rack  310  is completed, the AMR  246  undocks the rack  310  from the storage structure  230  ( 2014 ) and the AMR  246  transports the rack  310  to a new destination ( 2016 ). The AMR  246  may they stay engaged, or the AMR  246  may disengage from the rack  310  upon arrival at the new destination ( 2018 ). 
       FIG. 21  is a flowchart for using the truck in  FIG. 14  to deliver grocery orders to customers. In step  2100 , a rack  110  may be docked to a docking station  236  of a storage structure  230 , and bots may transfer totes to and/or from rack  110  ( 2102 ). When tote transfer is complete, rack  110  may undock from docking station  236  either manually or automatedly positioned on an AMR  246  ( 2104 ), and the rack  110  may be manually or automatedly transported to a vehicle ( 2106 ) such as a truck  210  shown in  FIG. 14 . The rack  110  may be docked to the vehicle in step  2110  by itself or along with one or more of the racks  110 . The vehicle may include docking features that allow racks  110  to be secured within the vehicle. The one or more racks  110  are then transported ( 2112 ) by the vehicle to a delivery site(s) such as one or more homes, whereupon the one or more racks  110  are undocked from the vehicle and delivered to the site(s) ( 2114 ). Once deliveries are completed ( 2116 ), the truck may return to the order fulfillment facility and undock from the transport vehicle ( 2118 ). Once at the facility, a rack  110  may be transported ( 2120 ) to a docking station  236  and docked ( 2122 ). Thereafter, bots may transfer totes to and/or from rack  110  at the storage structure ( 2124 ). 
       FIG. 22  is a flowchart for decant like  FIG. 15 . In step  2200 , a rack  110  may be docked to a docking station  236  of a storage structure  230 , and bots may exchange full totes for empty totes within the rack  110  ( 2202 ). When tote transfer is complete, rack  110  may undock from docking station  236  either manually or automatedly positioned on an AMR  246  ( 2204 ), and the rack  110  may be manually or automatedly transported to a decant station ( 2206 ) such as a decant station  350  shown in  FIG. 15 . Empty totes may be removed from the rack  110  ( 2208 ), the empty totes may be filled with product inventory ( 2210 ), and the filled totes may be returned to the rack  110  ( 2212 ). Once the rack  110  is again filled with full totes ( 2214 ), the rack  110  may be manually or automatedly transported away from the decant station  350  ( 2216 ) to dock to a docking station  236  of a storage structure  230  ( 2218 ). Thereafter, bots may again exchange full totes for empty totes within the rack  110  ( 2220 ). 
       FIG. 23  is a flowchart for replenishing the automation using a rack and pulling inventory from the store floor. In step  2300 , a rack  110  may be docked to a docking station  236  of a storage structure  230 , and bots may exchange full totes for empty totes in the rack  110  ( 2302 ). When tote transfer is complete, rack  110  may undock from docking station  236  either manually or automatedly positioned on an AMR  246  ( 2304 ), and the rack  110  may be manually or automatedly transported to the store floor ( 2306 ). There, empty totes may be removed from the rack  110  ( 2310 ), filled with product from the store floor ( 2312 ), and returned to the rack  110  ( 2314 ). Once the rack  110  is again filled with full totes ( 2316 ), the rack  110  may be manually or automatedly transported from the store floor ( 2318 ) to dock to a docking station  236  of a storage structure  230  ( 2320 ). Thereafter, bots may again exchange full totes for empty totes within the rack  110  ( 2320 ). 
     The rack  110  may be docked to the vehicle in step  1708  by itself or along with one or more of the racks  110 . The vehicle may include docking features that allow racks  110  to be secured within the vehicle. The one or more racks  110  are then transported by the vehicle to an alternate site ( 1710 ), whereupon the one or more racks  110  are undocked from the vehicle ( 1712 ) and transported away from the vehicle into the new site ( 1714 ). In step  1716 , a rack  110  may be docked to a docking station  236  of a storage structure  230  at the new site (storage structure B), and bots may transfer totes to and/or from rack  110  at storage structure B ( 1718 ). 
     The foregoing detailed description has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the description to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The described embodiments were chosen in order to best explain the principles of the claimed system and its practical application to thereby enable others skilled in the art to best utilize the claimed system in various embodiments and with various modifications as are suited to the particular use contemplated.