Patent ID: 12214961

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

First of all, it is to be noted that in the different embodiments described, equal parts are provided with equal reference numbers and/or equal component designations, where the disclosures contained in the entire description may be analogously transferred to equal parts with equal reference numbers and/or equal component designations. Moreover, the specifications of location, such as at the top, at the bottom, at the side, chosen in the description refer to the directly described and depicted figure, and in case of a change of position, are to be analogously transferred to the new position.

FIGS.1,2aand2bshow a first embodiment of an order fulfillment facility1afor storing and picking article carriers3that contain articles2(as only shown inFIG.4bfor reasons of clarity) and are stackable. The order fulfillment facility1acomprises a delivery zone4, a storage zone5, an order processing zone6, a plurality of transport loading aids7each for accommodating and stabilizing the position of at least one article carrier stack8and a plurality of autonomously moveable, driverless transport vehicles9for transporting transport loading aids7. The article carrier stack8is formed by multiple article carriers3arranged (stacked) on top of one another.

In the delivery zone4, the provision of article carrier stacks8is envisaged. The article carrier stacks8can be provided as separate article carrier stacks8and/or as article carrier stack groups10assembled of article carrier stacks8arranged next to one another. In general, the provision of individual article carriers3would also be possible.

Usually, the article carrier stacks8are delivered into the delivery zone4as article carrier stack groups10on pallets or roll containers (delivery load carrier). In this case, an article carrier stack group10of a depalletizing station is supplied, in which article carrier stacks8of multiple article carriers3, arranged on top of one another, from one article carrier stack group10are separated. Such article carrier stack groups10are most times made up of article carrier stacks8containing articles of just one type.

In contrast to this, the separated article carrier stacks8are delivered into the delivery zone4without pallets or roll containers (delivery load carrier). In this case, the article carrier stacks8do not have to be fed to a depalletizing station and a depalletizing station can be dispensed with.

FIGS.1and2bshow a possible embodiment, in which a depalletizing station with at least one automatically operated depalletizing device11(schematically adumbrated), a first conveying device12afollowing the depalletizing device11for supplying article carrier stack groups10(incoming article units), a second conveying device12bfollowing the depalletizing device11for transporting delivery load carriers away, a loading station with at least one automatically operated loading device13(schematically adumbrated), a third conveying device14aconnecting, in respect of a conveying stream, the depalletizing device11to the loading station13for supplying article carrier stacks8and/or a fourth conveying device14bconnecting, in respect of a conveying stream, the depalletizing device11to the loading station13for supplying article carrier stacks8may be provided in the delivery zone4. The fourth conveying device14bfor supplying article carrier stacks8is optional and may also be omitted.

As not shown in further detail, for example, the depalletizing device11can rotate, clamp and lift the article carrier stacks8along the circumference on at least two sides and/or lower the delivery load carrier (pallet) and discharge it using the second conveyor device12band deliver the article carrier stacks8to the third conveyor device14aand the fourth conveyor device14b, by means of which the article carrier stacks8can be further transported individually and/or in pairs. The article carrier stacks8are provided at the loading device13“unamendedly” and each in a transfer position. The first transfer location15ais preferably formed on the third conveying device14aand the second transfer location15bis preferably formed on the fourth conveying device14b. In case the fourth conveying device14bis not provided, only the transfer location15ais provided.

As described in the following, the loading station comprises the at least one automatically operated loading device13(schematically adumbrated) and additionally a buffer surface30near said loading device13.

The schematically depicted loading device13comprises a first provisioning location16afor the first transport loading aid7a, an (optional) second provisioning location16bfor the second transport loading aid7band a transfer device17for transferring a first article carrier stack8from the first transfer location15aonto the first transport loading aid7aand possibly for transferring a second article carrier stack8from the second transfer location15bonto the second transport loading aid7b. The first provisioning location16aand the first transfer location15aare arranged so as to be located opposite one another. The optional (second) provisioning location16band the optional (second) transfer location15bare arranged so as to be located opposite one another.

In concrete terms, the automatically operated loading device13comprises a transfer device17that is movable relative to the transfer location15a,15bin order to move an article carrier stack8(or possibly individual article carriers3) provided in a transfer position at the transfer location15a,15bto the transport loading aid7a,7b. The transfer device17may be formed for example by a pusher actuatable by an actuating drive. The transfer device17is arranged above the conveying device14a,14b.

According to a first embodiment, the loading device13may specifically comprise a gantry robot. Gantry robots are understood to be industrial robots, which in their base axes are constructed from linear axles. Using a line gantry is sufficient for loading.

The gantry robot comprises vertical uprights, longitudinal beams and transverse beams, which are connected to one another, forming a support construction18. Additionally, the gantry robot comprises a gantry slide19, that is movable in a first direction (x-direction-horizontal movement) along a guide assembly via a first drive device, and a gantry arm20arranged on the gantry slide19. A transfer device17is arranged on the gantry arm20. The first drive device comprises a traction drive connected to the gantry slide19. The traction drive comprises an endlessly revolving traction means, which is guided around a deflection wheel and a drive wheel coupled with an electric actuating motor. A clockwise or counter-clockwise rotating motion of the drive wheel moves the gantry slide19and the transfer device17mounted thereon relative to the transfer location15a,15beither in a first pushing direction or second pushing direction (x-direction). The gantry robot may comprise a displacement measurement device not depicted, by means of which the readjustment movements of the gantry slide19(and/or of the transfer device17) are captured. Here, the measurement method of absolute and incremental displacement measurement is utilized.

It may prove useful if the gantry arm20is also movable in a second direction (z-direction-vertical movement) along a guide assembly via a second drive device.

In the course of the pushing movement, the first article carrier stack8ais moved from the first transfer location15aonto the empty first transport loading aid7a, which is provided at the provisioning location16a, or the second article carrier stack8bis moved from the second transfer location15bonto the empty second transport loading aid7b, which is provided at the second provisioning location17b. InFIG.2b, the first article carrier stack8ahas already been discharged onto the first transport loading aid7a, while the second article carrier stack8bis still being transported to the loading device13and the second transport loading aid7bis still empty.

The described loading device13may be constructed very simply and requires on principle only a stationary holding surface (transfer location15a,15b) and a pushing device (pusher), by means of which the “unamended” article carrier stack8is pushed from the holding surface onto the empty (first) transport loading aid.

According to an embodiment, which is not depicted, the loading device13may comprise a jointed-arm robot. The jointed-arm robot comprises a gripping system that is movable relative to a robot base, by means of which gripping system an “unamended” article carrier stack8(or possibly individual article carriers3) can be transferred from the transfer position on the first/second transfer location15a,15bto the first transport loading aid7a/second transport loading aid7b. In this regard, the “unamended” article carrier stack8can be pushed from the holding surface (transfer location15a,15b) onto the empty (first) transport loading aid or individual article carriers3can be lifted off the article carrier stack8and placed on the empty (first) transport loading aid7a,7b.

As depicted inFIG.2b, an empty (first) transport loading aid7cmay be transported to the provisioning location16a,16busing an autonomously moveable, driverless transport vehicle9and be placed there. While loading the (first) transport loading aid7,7a. . .7c, said transport vehicle9may be used for other transport purposes.

However, in principle, it is also possible that the autonomously moveable, driverless transport vehicle9is transported to the provisioning location16a,16band placed there but remains at the provisioning location16a,16bwhile the (first) transport loading aid7a,7bis loaded. This is particularly advantageous if loading the (first) transport loading aid7,7a. . .7ctakes place with an “unamended” article carrier stack8,8a. . .8cas this allows loading to be performed particularly quickly and the transport vehicle9is “unproductive” only for a short time.

If a (first) transport loading aid7a,7bis already placed at the provisioning location16aor if (first) transport loading aids7a,7bare already placed at the provisioning locations16a,16bor if the (first) transport loading aid7ais or the (first) transport loading aids7a,7bare currently being loaded, the empty (first) transport loading aids7c,7dcan be buffered on the buffer surface30provided near the loading device13.

Even though, in the depicted embodiment, the loading station is shown having a single loading device13for reasons of clarity, the number of loading devices13may vary depending on the required picking performance. For example, the loading station and/or the order fulfillment facility1amay have a second loading device13, third loading device13etc. These loading devices13are preferably constructed identically. It also proves advantageous if a separate buffer surface30is arranged near each loading device13. However, in principle, the loading station may also comprise only one buffer surface30. The buffer surface30is preferably formed on a base of the order fulfillment facility1a.

This way, it is possible that the empty (first) transport loading aid(s)7dare buffered on the buffer surface30, near the loading device(s)13, and are transported as needed to the respective provisioning location16a,16bof the loading device(s)13over a short distance using the transport vehicles9.

After being loaded (with at least one article carrier stack8), the (first) transport loading aids7eare transported from the loading station, in particular from the first loading station13, or from the first loading devices13to the storage zone5using the autonomously moveable, driverless transport vehicles9and are placed on a storage area31in the storage zone5. The storage surface31is preferably formed on a base of the order fulfillment facility1a. As will be described below, using the autonomously moveable, driverless transport vehicles9, also at the unloading station, not completely unloaded (partially loaded) “opened” (first) transport loading aids7fare transported from the unloading station back to the storage zone5and placed on the storage surface31in the storage zone5.

As evident inFIGS.1and2a, an unloading station with at least one automatically operated unloading device32(schematically adumbrated), a first conveying device33following the unloading device32for transporting completely loaded target loading aids34a(outgoing article units) away and optionally a second conveying device35following the unloading device32for supplying empty target loading aids34bare arranged in the order processing zone6. According to this embodiment, the unloading station with the automatically operated unloading device32or the multiple automatically operated unloading devices32simultaneously forms a reloading station with the one automatically operated reloading device (palletizing device) or the multiple automatically operated reloading devices (palletizing devices), by means of which the article carriers3or article carrier stacks8are transferred from the transport loading aid7onto the target loading aid34cor the target loading aids34c. Therefore, the term “unloading device” may be used synonymously with “reloading device”.

As described in the following, the unloading station comprises the at least one automatically operated unloading device32(schematically adumbrated). Even though, in the depicted embodiment, the unloading station is shown having a single unloading device32for reasons of clarity, the number of unloading devices32may vary depending on the required picking performance. For example, the unloading station and/or the order fulfillment facility1amay have a second unloading device32, third unloading device32etc. These unloading devices32are preferably constructed identically.

It also proves advantageous if the unloading station has at least one separate buffer surface36near the unloading device32or near each unloading device32. In the depicted embodiment, the unloading device32is assigned one buffer surface36per provisioning location40a. . .40b. However, in principle, the unloading station may also comprise only one buffer surface36. The buffer surface36is preferably formed on a base of the order fulfillment facility1a. This way, it is possible that the loaded (first) transport loading aid(s)7gare buffered on the buffer surface36, near the unloading device(s)32, and are transported as needed to the respective provisioning location40a. . .40bof the unloading device(s)32over a short distance using the transport vehicles9.

It is also advantageous if the unloading station has one or multiple waiting zone(s)37. A transport loading aid7hcan be placed at the waiting zone37or at the waiting zones37after removing of at least one article carrier3, if not all article carriers3have been removed from the mentioned transport loading aid7hand if these article carriers3are needed at the mentioned unloading device32or one of the unloading devices32for an already advised picking order. However, in principle, the loading station may also comprise only one waiting zone37.

This way, it is possible that the partially unloaded (first) transport loading aid(s)7hare buffered in the waiting zone37, near the unloading device(s)32, and are transported as needed to the respective provisioning location40a. . .40bof the unloading device(s)32over a short distance using the transport vehicles9.

The schematically shown embodiment of the automatically operated unloading device32comprises a first provisioning location40afor the loaded first transport loading aid7i, an (optional) second provisioning location40bfor the loaded second transport loading aid7iand a transfer device41movable relative to the provisioning location40a. . .40bfor unloading the transport loading aid7iprovided at the provisioning location40a. . .40b. If the unloading station has more than one automatically operated unloading device32, each unloading device32comprises a first provisioning location40afor the loaded first transport loading aid7i, and an (optional) second provisioning location40bfor the loaded second transport loading aid7iand a transfer device41movable relative to the provisioning location40a. . .40bfor unloading the transport loading aid7iprovided at the provisioning location40a,40b.

The transfer device41may for example be formed by a gripping system. The gripping system may comprise for example a base body, a vacuum suction unit with at least one suction gripper or multiple suction grippers and/or adjacently arranged on top of one another (and/or next to one another) and a support base movably mounted on the base body. Unloading the transport loading aid7iwith this gripping system is performed such that an article carrier3or a partial article carrier stack is first lifted on one side by the suction unit so that a gap opens between the top article carrier3and the one below it and the support base is then pushed in under the article carrier3lifted on one side or the partial article carrier stack lifted on one side using the suction unit in a horizontal direction so as to accommodate said article carrier3or partial article carrier stack. Such a gripping system thus makes it possible to unload an individual article carrier3but also a partial article carrier stack. In principle, it is also conceivable that the number of suction grippers arranged on top of one another is selected such that the entire article carrier stack8can be lifted on one side and the support base can accommodate the entire article carrier stack8.

Moreover, the gripping system may also be configured such that a gripping unit acts according to the positive engagement principle and/or friction principle and grips an individual article carrier3, partial article carrier stack or article carrier stack8in a positively engaging or friction-type manner.

According to a first embodiment, the unloading device32may specifically comprise a gantry robot. Gantry robots are understood to be industrial robots, which in their base axes are constructed from linear axles. An area gantry is used for loading.

The gantry robot comprisesi) vertical uprights, longitudinal beams and transverse beams, which are connected to one another, forming a support construction42ii) a first gantry slide43mounted on the support structure42and horizontally movable in a first direction (x-direction) along a guide assembly (which are arranged on the longitudinal beams) via a first drive device,iii) a second gantry slide44mounted on the first gantry slide43and horizontally movable in a second direction (y-direction) along a guide assembly via a second drive device, andiv) a gantry arm45mounted on the second gantry slide44and vertically movable in a third direction (z-direction) along a guide assembly via a third drive device, andv) the transfer device41, which is arranged on the gantry arm45and is mounted on the gantry arm45so as to be rotatable about a vertical axis.

The first drive device comprises a first traction drive connected to the first gantry slide43. The first traction drive comprises endlessly revolving traction means, each of which is guided around a deflection wheel and a drive wheel. The drive wheels are coupled to an electric actuating motor. A clockwise or counter-clockwise rotating motion of the drive wheels moves the first gantry slide43and transfer device41mounted thereon in the x-direction relative to the provisioning location40a. . .40b.

The second drive device comprises a second traction drive connected to the second gantry slide44. The traction drive comprises an endlessly revolving traction means, which is guided around a deflection wheel and a drive wheel coupled with an electric actuating motor. A clockwise or counter-clockwise rotating motion of the drive wheel moves the second gantry slide44and transfer device41mounted thereon in the y-direction relative to the provisioning location40a. . .40b.

The third drive device comprises a traction drive (not shown) connected to the second gantry slide44. The traction drive comprises an endlessly revolving traction means, which is guided around a deflection wheel and a drive wheel coupled with an electric actuating motor. A clockwise or counter-clockwise rotating motion of the drive wheel moves the gantry arm45and transfer device41mounted thereon in the z-direction relative to the provisioning location40a. . .40b.

The adjustment movements of the first gantry slide43, the second gantry slide44, the gantry arm45and/or the transfer device41can be detected by the displacement measurement devices not depicted. Here, the measurement method of absolute and incremental displacement measurement is utilized.

In the course of the unloading movement, the article carrier3, partial article carrier stack or article carrier stack8is picked up from the transport loading aid7iby the gripping system, which is provided at the provisioning location40a. . .40b, and subsequently transferred onto a target loading aid34c.

According to an embodiment, which is not depicted, the unloading device32(reloading device) may comprise a jointed-arm robot. The jointed-arm robot comprises the gripping system, which is described above and movable relative to a robot base, by means of which individual article carriers3, partial article carrier stacks or “unamended” article carrier stacks8can be transferred from the first transport loading aid7i/second transport loading aid7ionto the target loading aid34c.

As schematically depicted inFIG.1, the order fulfillment facility1acomprises an order-processing computer46for detecting picking orders and for determining articles2which are required for the picking order. In this regard, a picking order comprises one order line (for example six article carriers3with a first article2) or multiple order lines (for example three article carriers3with a first article2and three article carriers3with a second article2). A sales order comprises at least one picking order. The picking orders are present in the form of data sets and are electronically detected by the order-processing computer46and transmitted to a control system47. Each picking order comprises one or multiple order lines. If the picking order specifies multiple order lines, different articles2are needed. Each order line has at least specifications on a number of pieces of an ordered article2and on a type of article.

For transporting the empty transport loading aids7and transport loading aids7loaded with article carrier stacks, autonomously moveable, steerable transport vehicles9(of a driverless transport system) are used, which are automatically controlled by a superordinate main computer. The control system47may comprise said main computer.

FIG.3shows a possible embodiment of one of the autonomously moveable, steerable transport vehicles9. The transport vehicle9is configured as a floor conveyor.

The transport vehicle9comprises a chassis50with a drive unit and a loading platform51arranged on the underframe50for picking up/discharging/transporting a mobile (non-stationary) transport loading aid7and/or a mobile (non-stationary) transport loading aid107and/or a mobile (non-stationary) transport loading aid150and/or a mobile (non-stationary) stack loading aid100aand/or a mobile (non-stationary) stack loading aid100b. The drive unit comprises wheels52,53rotatably mounted on the chassis50, of which at least one of the wheels52is coupled with a drive (not depicted) and at least one of the wheels53can be steered. It is also possible for both wheels52to be coupled with the drive and be driven by it. However, the transport vehicle9may also comprise four wheels, of which two wheels can be steered.

According to the shown embodiment, the loading platform51is mounted on the chassis50so as to be adjustable between an initial position (represented in continuous lines) and a transport position (represented in dashed lines). In the initial position, a transport loading aid7,7a. . .7iplaced on the base of the order fulfillment facility1a, in particular on a buffer surface30,36, of the storage surface31, in the waiting zone37or at the provisioning location16a,16b,40a,40b, can be driven under, in order to accommodate said transport loading aid7,7a. . .7ion the loading platform51. If the loading platform51is adjusted out of the initial position in the direction of the transport position, a transport loading aid7,7a. . .7iplaced on the base can be lifted and subsequently transported. In the transport position, the transport loading aid7,7a. . .7iis lifted off the base of the order fulfillment facility1aand it can be transported between the delivery zone4, storage zone5and the order processing zone6. If the loading platform51is adjusted out of the transport position in the direction of the initial position, the transport loading aid7,7a. . .7ican be placed on the base.

The transport vehicle9further comprises a travel control54, represented schematically in dashed lines, for receiving commands from the superordinate main computer and for controlling/regulating the movements of the autonomous transport vehicle9. The travel control54may also comprise means for (wirelessly) transfer data to and from the transport vehicle9. Finally, the transport vehicle9comprises sensors, which are not shown, for detecting the environment of the autonomous transport vehicle9and for spatial orientation. The drive of the drive unit and the sensors are connected to the travel control54.

FIGS.4aand4bshow a first embodiment of a transport loading aid7.FIG.4ashows the unloaded, empty transport loading aid7andFIG.4bshows the loaded transport loading aid7. The transport loading aid7comprises a base55and side walls56a,56b,56cconnected thereto for the stabilization of the position of the article carrier stack8and a loading and unloading opening57located opposite the side wall56c. The side walls56a,56b,56care preferably designed essentially at the height of the article carrier stack8, however at least at a sufficient height for the topmost article carrier3in the article carrier stack8to be surrounded by the side walls56a,56b,56cat least in some regions. Preferably, the loading and unloading opening57extends over the entire height of the side walls56a,56b.

The transport loading aid7may comprise first side walls56a,56brunning in parallel to one another or (as shown) first side walls56a,56bdiverging in the direction towards the loading and unloading opening57. The latter embodiment allows loading and/or unloading the transport loading aid7easily. The second side wall56cextends between the first side walls56a,56band is arranged in the edge region of the base55such that the side walls56a,56b,56cdelimit a single accommodating shaft in which the article carrier stack8can be accommodated for transport/for storage.

The base55comprises on its upper side a placing surface58, on which the article carrier stack8can be placed, and on its bottom side a transport surface59, against which the loading platform51of the transport vehicle9can be placed.

Additionally, the transport loading aid7may comprise adjustable feet60which are affixed to the base55. The transport loading aid7is placed via the adjustable feet60on the base. In an embodiment that is not shown, wheels instead of adjustable feet60may also be provided on the base55.

In the different embodiments of the order fulfillment facilities1a,1b,1c, the transport loading aid7described inFIGS.4aand4bis used. It is self-evident that the embodiments of the transport loading aids7′,7″,107described in the following can also be used in the order fulfillment facilities1a,1b,1c.

FIGS.5aand5bshow a second embodiment of a transport loading aid7′.FIG.5ashows the unloaded, empty transport loading aid7′ andFIG.5bshows the loaded transport loading aid7′. Such a transport loading aid7′ can provide multiple article carrier stacks8,8′,8″ consecutively at the provisioning locations16a,16b,40a,40b,67a,67b,77a,77bby a “rotating motion” about the vertical axis. The “rotating motion” is preferably performed by a transport vehicle9.

The transport loading aid7′ again comprises the base55and side walls56a,56b,56cconnected thereto, each for the stabilization of the position of article carrier stacks8and a first loading and unloading opening57alocated opposite the side wall56con a first side, and a second loading and unloading opening57blocated opposite the side wall56con a second side. The side walls56a,56b,56care preferably designed essentially at the height of the article carrier stack8, however at least at a sufficient height for the topmost article carrier3in the article carrier stack8to be surrounded by the side walls56a,56b,56cat least in some regions. Preferably, the first/second loading and unloading opening57each extend over the entire height of the side walls56a,56b.

The transport loading aid7′ can comprise first side walls56a,56brunning in parallel to one another. It proves to be advantageous if the first side walls56a,56bare configured having lead-in chamfers61for making an easy loading and/or unloading of the transport loading aid7′ possible. The second side wall56cextends between the first side walls56a,56band is arranged in the center region of the base55such that the side walls56a,56b,56cdelimit two accommodating shafts, in each of which at least one article carrier stack8can be accommodated for transport/for storage. In the depicted embodiment, one article carrier stack8with a base area of the article carriers of 600 mm×400 mm is accommodated in the first accommodation shaft, and two article carrier stacks8each with a base area of the article carriers of 300 mm×400 mm are accommodated in the second accommodation shaft. This transport loading aid7′ can transport multiple article carrier stacks8simultaneously. In principle, however, the side wall56ccould also be omitted, so that only one accommodation shaft is present, in which one or more article carrier stacks8can be accommodated.

The base55again comprises on its upper side a placing surface58, on which the article carrier stacks8can be placed, and on its bottom side a transport surface59, against which the loading platform51of the transport vehicle9can be placed.

Additionally, the transport loading aid7′ may comprise adjustable feet60which are affixed to the base55. The transport loading aid7′ is placed via the adjustable feet60on the base. In an embodiment that is not shown, wheels instead of adjustable feet60may also be provided on the base55.

FIGS.6aand6bshow a third embodiment of a transport loading aid7″.FIG.6ashows the unloaded, empty transport loading aid7″ andFIG.6bshows the loaded transport loading aid7″. Such a transport loading aid7′ can provide multiple article carrier stacks8,8′,8″ consecutively at the provisioning locations16a,16b,40a,40b,67a,67b,77a,77bby a short “offset motion”. The “offset motion” is preferably performed by a transport vehicle9.

The transport loading aid7″ again comprises the base55and side walls56a,56b,56c,56dconnected thereto, each for the stabilization of the position of article carrier stacks8and loading and unloading openings57a,57blocated opposite the side wall56con a single side. The side walls56a,56b,56c,56dare preferably designed essentially at the height of the article carrier stack8, however at least at a sufficient height for the topmost article carrier3in the article carrier stack8to be surrounded by the side walls56a,56b,56c,56dat least in some regions. Preferably, the first/second loading and unloading opening57each extend over the entire height of the side walls56a,56b,56d.

The transport loading aid7″ may comprise outer first side walls56a,56brunning in parallel to one another and a parallel inner side wall56d. The second side wall56cextends between the first side walls56a,56b,56d. The inner first side wall56dis arranged in the center region of the base55such that the side walls56a,56b,56c,56ddelimit two accommodating shafts, in each of which at least one article carrier stack8can be accommodated for transport/for storage. In the depicted embodiment, one article carrier stack8with a base area of the article carriers of 600 mm×400 mm is accommodated in the first accommodation shaft, and two article carrier stacks8each with a base area of the article carriers of 300 mm×400 mm are accommodated in the second accommodation shaft. This transport loading aid7″ can transport multiple article carrier stacks8simultaneously.

It proves to be advantageous if the outer first side walls56a,56band possibly also the inner first side wall56dare configured having lead-in chamfers (not depicted) for making an easy loading and/or unloading of the transport loading aid7″ possible.

The base55again comprises on its upper side a placing surface58, on which the article carrier stacks8can be placed, and on its bottom side a transport surface59, against which the loading platform51of the transport vehicle9can be placed.

It should also be noted at this point that the transport loading aid7,7′,7″ may have centering elements (not depicted) on the first side walls56a,56b,56dor on the first side walls56a,56b,56dand on the second side wall56cand facing the respective accommodating shaft, which centering elements can be used to center the article carriers3/article carrier stacks8and to stabilize the position of the article carriers3/article carrier stacks8.

FIG.7shows a second embodiment of an order fulfillment facility1bfor storing and picking article carriers3that contain articles2and are stackable. The order fulfillment facility1bagain comprises the delivery zone4, the storage zone5, the order processing zone6, a plurality of transport loading aids7each for accommodating and stabilizing the position of at least one article carrier stack8and a plurality of autonomously moveable, driverless transport vehicles9for transporting transport loading aids7.

This embodiment is different with respect to the order fulfillment facility1ain that an unloading station separate of the reloading station is provided in the order processing zone6.

The unloading station shown in an enlarged view inFIG.7acomprises the at least one automatically operated unloading device65(schematically adumbrated). Even though, in the depicted embodiment, the unloading station is shown having a single unloading device65for reasons of clarity, the number of unloading devices65may vary depending on the required picking performance. For example, the unloading station and/or the order fulfillment facility1bmay have a second unloading device65, third unloading device65etc. These unloading devices65are preferably constructed identically.

It also proves advantageous if the unloading station has at least one separate buffer surface66near the unloading device65or near each unloading device65. In the depicted embodiment, the unloading device66is assigned one buffer surface66a,66bper provisioning location67a,67b. However, in principle, the unloading station may also comprise only one buffer surface66. The buffer surface66is preferably formed on a base of the order fulfillment facility1b. This way, it is possible that the loaded (first) transport loading aid(s)7g, not shown here, are buffered on the buffer surface66, near the unloading device(s)65, and are transported as needed to the respective provisioning location67a,67bof the unloading device(s)65over a short distance using the transport vehicles9.

The reloading station comprises the at least one reloading device32(schematically adumbrated) operated in an automated manner, as described above. Even though, in the depicted embodiment, the unloading station is shown having a single reloading device32for reasons of clarity, the number of reloading devices32may vary depending on the required picking performance. For example, the reloading station and/or the order fulfillment facility1bmay have a second reloading device32, third reloading device32etc. These reloading devices32are preferably constructed identically.

According to this embodiment, a fixed-installation conveying system is arranged between the unloading station and the reloading station, by means of which conveying device article carriers3, partial article carrier stacks or article carrier stacks8are transported from the unloading device65or the unloading devices65to the reloading device32or reloading devices32. In the course of this, the article carriers3required for a picking order are assembled on the fixed-installation conveying system by the unloading device65.

As is evident inFIG.7a, the fixed-installation conveying system comprises a first conveying device68afor supplying article carriers3, partial article carrier stacks or article carrier stacks8and/or a second conveying device68bfor supplying article carriers3, partial article carrier stacks or article carrier stacks8. The second conveying device68bfor supplying article carriers3, partial article carrier stacks or article carrier stacks8is optional and may also be omitted.

The schematically shown unloading device65comprises a first provisioning location67afor the loaded first transport loading aid7, an (optional) second provisioning location67bfor the loaded second transport loading aid7and a transfer device69movable relative to the provisioning location67a,67bfor unloading the transport loading aid7provided at the provisioning location67a,67b. The transport loading aid7at the provisioning location67ais yet to be unloaded while the transport loading aid7at the provisioning location67bhas already been unloaded. During the unloading operation, an article carrier3, partial article carrier stack or the article carrier stack8is transferred from the first transport loading aid7to a first take-over location70aand possibly an article carrier3, partial article carrier stack or the article carrier stack8is transferred from the second transport loading aid7to a second take-over location70b.

The first take-over location70aand the second take-over location70bare formed on the fixed-installation conveying system. In concrete terms, the first take-over location70ais formed on the first conveying device68aand the second take-over location70bis formed on the second conveying device68b. In case the second conveying device70bis not provided, only the first take-over location70ais provided. The first provisioning location67aand the first take-over location70aare arranged so as to be located opposite one another. The optional (second) provisioning location70band the optional (second) take-over location70bare arranged so as to be located opposite one another. The transfer device69is arranged above the conveying device68a,68b.

The transfer device69may for example be formed by a gripping system. The gripping system may comprise for example a base body, a vacuum suction unit with at least one suction gripper or multiple suction grippers arranged on top of one another and a support base movably mounted on the base body, as described above and transferable to the unloading device65.

Moreover, the gripping system may also be configured such that a gripping unit acts according to the positive engagement principle and/or friction principle and grips an individual article carrier3, article carrier partial stack or article carrier stack8in a positively engaging or friction-type manner.

According to a first embodiment, the unloading device65may specifically comprise a gantry robot which constructively corresponds to the loading device13. Gantry robots are understood to be industrial robots, which in their base axes are constructed from linear axles. Using a line gantry is sufficient for loading.

The gantry robot comprises vertical uprights, longitudinal beams and transverse beams, which are connected to one another, forming a support construction18. Additionally, the gantry robot comprises a gantry slide19, that is movable in a first direction (x-direction-horizontal movement) along a guide assembly via a first drive device, and a gantry arm20arranged on the gantry slide19. A transfer device69is arranged on the gantry arm20. The first drive device comprises a traction drive connected to the gantry slide19. The traction drive comprises an endlessly revolving traction means, which is guided around a deflection wheel and a drive wheel coupled with an electric actuating motor. A clockwise or counter-clockwise rotating motion of the drive wheel moves the gantry slide19and the transfer device69mounted thereon relative to the provisioning location67a,67beither in a first unloading direction or second unloading direction (x-direction).

The gantry arm20is movable along a guide assembly in a second direction (z-direction-vertical movement) via a second drive device. The transfer device69(gripping system) is mounted on the gantry arm20so as to be rotatable about a vertical axis.

The adjustment movements of the gantry slide19, the gantry arm20and/or the transfer device69can be detected by the displacement measurement devices not depicted. Here, the measurement method of absolute and incremental displacement measurement is utilized.

In the course of the unloading movement, the article carrier3, partial article carrier stack or article carrier stack8is picked up from the transport loading aid7by the gripping system, which is provided at the provisioning location67a,67b, and subsequently discharged onto the take-over location70a,70b.

According to an embodiment, which is not depicted, the unloading device65may comprise a jointed-arm robot. The jointed-arm robot comprises a gripping system that is movable relative to a robot base, by means of which gripping system an article carrier3, partial article carrier stack or an “unamended” article carrier stack8can be transferred from the first transport loading aid7/second transport loading aid7onto the take-over location70a,70b.

After the unloading operation, the article carriers3, partial article carrier stacks or article carrier stacks8are transported, by the fixed-installation conveying system, in particular the first conveying device68aand/or second conveying device68b, from the unloading device(s)65to the automatically operated reloading device(s)32(palletizing device(s)), and provided at one or multiple provisioning locations71a,71bon the fixed-installation conveying system.

The reloading device32can take over the article carriers3, partial article carrier stacks or article carrier stacks8successively from the provisioning location/the provisioning locations70a. . .70bwith the transfer device41(gripping system) in the manner described above and subsequently place them on the target loading aid34c.

It is noted at this point that according to this embodiment as well, the reloading device32can be formed for example by the gantry robot or jointed-arm robot described above. To avoid repetition reference is made to the above disclosure.

FIG.8shows a third embodiment of an order fulfillment facility1cfor storing and picking article carriers3that contain articles2and are stackable. The order fulfillment facility1cagain comprises the delivery zone4, the storage zone5, the order processing zone6, a plurality of transport loading aids7each for accommodating and stabilizing the position of at least one article carrier stack8and a plurality of autonomously moveable, driverless transport vehicles9for transporting transport loading aids7.

This embodiment is different with respect to the order fulfillment facility1ain that an unloading station separate of the reloading station is provided in the order processing zone6.

The unloading station comprises the at least one unloading device75(schematically adumbrated) operated in an automated manner. Even though, in the depicted embodiment, the unloading station is shown having a single unloading device75for reasons of clarity, the number of unloading devices75may vary depending on the required picking performance. For example, the unloading station and/or the order fulfillment facility1cmay have a second unloading device75, third unloading device75etc. These unloading devices75are preferably constructed identically.

It also proves advantageous if the unloading station has at least one separate buffer surface76near the unloading device75or near each unloading device75. In the depicted embodiment, in the unloading device75, a provisioning location77ais assigned a buffer surface76aand a provisioning location77bis assigned a buffer surface76b. The buffer surface76,76a,76bis preferably formed on a base of the order fulfillment facility1c.

This way, on the one hand, it is possible that a loaded transport loading aid7g, not shown here, is buffered on the buffer surface76a, near the unloading device(s)75, and is transported as needed to the respective provisioning location77aof the unloading device(s)65over a short distance by a transport vehicle9. On the other hand, it is possible that an empty transport loading aid7d, not shown here, is buffered on the buffer surface76b, near the unloading device(s)75, and is transported as needed to the respective provisioning location77bof the unloading device(s)75over a short distance by a transport vehicle9.

The reloading station comprises at least one reloading device32(schematically adumbrated) operated in an automated manner. Even though, in the depicted embodiment, the unloading station is shown having a single reloading device32for reasons of clarity, the number of reloading devices32may vary depending on the required picking performance. For example, the reloading station and/or the order fulfillment facility1cmay have a second reloading device32, third reloading device32etc. These reloading devices32are preferably constructed identically.

To avoid repetition, reference is made to the above description with regard to the disclosure of the reloading station.

There is merely a difference in the provision of the article carrier stacks with the transport loading aids7at the first provisioning location40aand possibly second provisioning location40b. While, according to the first embodiment (FIG.1), the article carrier stacks are provided at the first provisioning location40aand possibly second provisioning location40bas article carrier stacks8containing articles of just one type, according to the embodiment shown (FIG.8), a first transport loading aid7iwith a first pre-picked article carrier stack8′ is provided at the first provisioning location40a, and possibly, a second transport loading aid7i, not shown, with a second pre-picked article carrier stack8′ is provided at the second provisioning location40b.

Picking article carriers3according to a picking order to form an article carrier stack8′ takes place in the unloading station using at least one automatically operated unloading device75.

The schematically depicted unloading device75comprises at least one first provisioning location77afor the first transport loading aid7a, which contains article carriers3containing articles of just one type and from which article carriers3can be removed according to a picking order, and at least one second provisioning location77bfor the second transport loading aid7b, onto which article carriers3are discharged according to a picking order, and a transfer device84, which is movable relative to the provisioning location77a,77b, for unloading the transport loading aid7aprovided at the provisioning location77aand for loading the transport loading aid7bprovided at the provisioning location77b. The first provisioning location77aand the second provisioning location77bare arranged so as to be located opposite one another. The transfer device84is arranged above the provisioning locations77a,77b.

If a picking order comprises different articles2, article carriers3are successively taken out of different transport loading aids7a. In order to do so, the transport loading aids7acan be provided successively at the provisioning location77a, and the required article carriers3can be unloaded successively and discharged onto the transport loading aids7b. In this regard, individual article carriers3or partial article carrier stacks can be taken from the first transport loading aid7aand discharged onto the second transport loading aid7b. If a picking order requires an entire article carrier stack8, it is removed from the storage area5using a transport vehicle9, as described above, and transported to the order processing zone6and provided at a provisioning location40a. . .40b.

The transfer device84may for example be formed by a gripping system. The gripping system may comprise for example a base body, a vacuum suction unit with at least one suction gripper or multiple suction grippers arranged on top of one another and a support base movably mounted on the base body, as described above and transferable to the unloading device75.

Moreover, the gripping system may also be configured such that a gripping unit acts according to the positive engagement principle and/or friction principle and grips an individual article carrier3or partial article carrier stack in a positively engaging or friction-type manner.

According to a first embodiment, the unloading device75may specifically comprise a gantry robot.

The gantry robot comprises vertical uprights, longitudinal beams and transverse beams, which are connected to one another, forming a support construction81. Additionally, the gantry robot comprises a gantry slide82, that is movable in a first direction (x-direction-horizontal movement) along a guide assembly via a first drive device, and a gantry arm83arranged on the gantry slide82. A transfer device84is arranged on the gantry arm83. The first drive device comprises a traction drive connected to the gantry slide82. The traction drive comprises an endlessly revolving traction means, which is guided around a deflection wheel and a drive wheel coupled with an electric actuating motor. A clockwise or counter-clockwise rotating motion of the drive wheel will move the gantry slide82and the transfer device84mounted thereon relative to the provisioning location77in an unloading direction (x-direction).

The gantry arm83is movable along a guide assembly in a second direction (z-direction-vertical movement) via a second drive device. The transfer device84(gripping system) is mounted on the gantry arm83so as to be rotatable about a vertical axis.

The gantry robot may comprise a displacement measurement device not depicted, by means of which the readjustment movements of the gantry slide82, gantry arm83and/or of the transfer device84are captured. Here, the measurement method of absolute and incremental displacement measurement is utilized.

In the course of the unloading movement, the article carrier3or partial article carrier stack is picked up by the gripping system from the transport loading aid7a, which is provided at the provisioning location77aand contains an article carrier stack8containing articles of just one type, and is subsequently discharged in the course of the loading movement of the article carriers3or partial article carrier stacks onto the transport loading aid7b, which is provided at the provisioning location77band in which article carriers3are picked.

After the loading operation, the transport loading aid7bwith the pre-picked article carrier stack8′ is transported to the reloading station using a transport vehicle9and is provided at the at least one reloading device32.

According to an embodiment, which is not depicted, the unloading device75may comprise a jointed-arm robot. The jointed-arm robot comprises a gripping system that is movable relative to a robot base, by means of which gripping system an article carrier3or partial article carrier stack can be removed from the first transport loading aid7aand transferred to the second transport loading aid7b.

In the following, the method for storing and picking article carriers3that contain articles2and are stackable in the order fulfillment facility1a(first embodiment) is described.

The method comprises the steps:i) providing autonomously moveable, driverless transport vehicles9,ii) providing transport loading aids7each for receiving and stabilizing the position of at least one article carrier stack8of multiple article carriers3arranged on top of one another, wherein the transport loading aids7comprise mobile, empty transport loading aids7,iii) providing article carrier stacks8of multiple article carriers3arranged on top of one another in a delivery zone4,iv) transporting empty transport loading aids7using the autonomously moveable, driverless transport vehicles9to a loading station and providing one or multiple empty (first) transport loading aid(s)7either on one or on multiple automatically operated loading device(s)13or on a buffer surface30close to the loading device(s)13,v) loading one of the empty transport loading aids7, which is provided at the automatically operated loading device13, with at least one article carrier stack8from the delivery zone4using the automatically operated loading device13,vi) transporting the transport loading aid7loaded with at least one article carrier stack8from the loading station to a storage zone5using the autonomously moveable, driverless transport vehicle9,vii) placing the transport loading aid7loaded with at least one article carrier stack7on a storage surface31in the storage zone5,viii) storing the transport loading aids7loaded with at least one article carrier stack8or the transport loading aids7loaded with individual article carriers3in the storage zone5,ix) processing a picking order comprising the steps:transporting one or multiple transport loading aid(s)7containing the article carriers3required for a picking order from the storage zone5to an unloading station and providing said transport loading aid(s)7either at one or at multiple automatically operated unloading device(s)32or on a buffer surface36close the unloading device(s)32using one or multiple autonomously moveable, driverless transport vehicle(s)9,unloading one or multiple ones of the transport loading aid(s)7, which is (are) provided at the automatically operated unloading device(s)32, by removing the article carriers3required for processing the mentioned picking order, andassembling the article carriers3on one or multiple target loading aid34using the unloading device(s)32for the mentioned picking order by the article carrier3or the at least one article carrier stack8being removed from the provided transport loading aid(s)7using the unloading device32and transferred from said unloading device32to the target loading aid(s)34.

Providing autonomously moveable, driverless transport vehicles9according to step i) may comprise providing transport vehicles9, which are used exclusively for transporting the transport loading aid(s)7between the delivery zone4(loading station) and the storage zone5, and may comprise providing transport vehicles9, which are used exclusively for transporting the transport loading aid(s)7between the storage zone5and the order processing zone6(removal station). However, step i) may just as well comprise providing transport vehicles9, which are used both for transporting the transport loading aid(s)7between the delivery zone4(loading station) and the storage zone5and for transporting the transport loading aid(s)7between the storage zone5and the order processing zone (removal zone).

Providing transport loading aids7according to step ii) may comprise providing structurally identical transport loading aids7or structurally different transport loading aids7. Likewise, structurally different transport loading aids7may be used in the order fulfillment facility1a.

On the one hand, step iii) may comprise providing separate article carrier stacks8without pallets or roll container (delivery load carriers).

On the other hand, step iii) may comprise providing article carrier stacks8as article carrier stack groups10on pallets or roll containers (delivery load carriers), which are previously fed to a depalletizing station in order to separate the article carrier stacks8out of an article carrier stack group10.

For example, the article carriers3may carry fruit or vegetables, wherein a first article carrier stack group10contains a first type of vegetable and a second article carrier stack group10contains a second type of vegetable.

Step iv) may comprise transporting empty transport loading aids7using the autonomously moveable, driverless transport vehicles9to a loading station and directly providing (an) empty loading aid(s)7on one or multiple automatically operated loading device(s)13.

However, step iv) may also comprise transporting empty transport loading aids7using the autonomously moveable, driverless transport vehicles9to a loading station onto a buffer surface30close to the loading device(s)13and transporting said empty transport loading aid(s)7using the autonomously moveable, driverless transport vehicles9to the loading device(s)13and providing said empty transport loading aid(s)7on one or multiple automatically operated loading device(s)13.

Providing an empty transport loading aid7on one or multiple automatically operated loading device(s)13according to step iv) may comprise the following step:placing the empty transport loading aid7at a provisioning location16a,16bhaving the relevant loading device13and having the transport vehicle9remain at the provisioning location16a,16bduring the loading operation of the empty transport loading aid7according to step v), orplacing the empty transport loading aid7at a provisioning location16a,16bhaving the relevant loading device13and subsequently having the transport vehicle9move on from the provisioning location16a,15b, thus even before the start or during the loading operation of the empty transport loading aid7according to step v).

The loading of the empty transport loading aids7according to step v) may comprise loading one of the empty transport loading aids7with at least one article carrier stack8and/or loading one of the empty transport loading aids7with at least one partial article carrier stack8and/or loading one of the empty transport loading aids7with individual article carriers3and/or a combination thereof.

Step ix) may comprise transporting loaded transport loading aids7using the autonomously moveable, driverless transport vehicles9from the storage zone5(but possibly also from the loading station in the delivery zone4) to an unloading station and directly providing (a) loaded loading aid(s)7on one or multiple automatically operated unloading device(s)32.

However, step ix) may also comprise transporting loaded transport loading aids7using the autonomously moveable, driverless transport vehicles9from the storage zone5(but possibly also from the loading station in the delivery zone4) to an unloading station onto a buffer surface36close to the unloading device(s)32and transporting said loaded transport loading aid(s)7using the autonomously moveable, driverless transport vehicles9from the buffer surface36to the unloading device(s)32and providing said loaded transport loading aid(s)7on one or multiple automatically operated unloading device(s)32.

The transport vehicles9may also be controlled by the main computer such that they arrive at the unloading station in a sequence provided by the packing order of the article carriers3at the target loading aid34. Thus, a sequencing of the transport loading aids7and/or article carrier stacks8is achieved.

Providing a loaded transport loading aid(s)7on one or multiple automatically operated loading device(s)32according to step ix) may comprise the following step:placing the loaded transport loading aid(s)7at a provisioning location40a. . .40bhaving the relevant unloading device32and having the transport vehicle9remain at the provisioning location40a. . .40bduring the unloading operation of the loaded transport loading aid(s)7according to step ix), orplacing the loaded transport loading aid(s)7at a provisioning location40a. . .40bhaving the relevant unloading device32and subsequently having the transport vehicle9move on from the provisioning location40a. . .40b, thus even before the start or during the unloading operation of the loaded transport loading aid(s)7according to step ix).

In the following, the method for storing and picking article carriers3that contain articles2and are stackable in the order fulfillment facility1b(second embodiment) is described.

The method comprises the steps i) to viii) as described above and the stepix) processing a picking order comprising the steps:transporting one or multiple transport loading aid(s)7containing the article carriers3required for a picking order from the storage zone5to an unloading station and providing said transport loading aid(s)7either at one or at multiple automatically operated unloading device(s)65or on a buffer surface66close the unloading device(s)65using one or multiple autonomously moveable, driverless transport vehicle(s)9,unloading one or multiple ones of the transport loading aid(s)7, which is (are) provided at the automatically operated unloading device(s)65, by removing the article carriers3required for processing the mentioned picking order, andassembling the article carrier3on one or multiple target loading aids34using the unloading device(s)32for the mentioned picking order by performing the assembly of the article carriers3for the mentioned picking order such that the article carriers3removed from the article carrier stack8at the unloading device(s)65or the at least one or the article carrier stack(s)8removed at the unloading device(s)65is (are) transferred to a fixed-installation conveying system using the provided transport loading aid(s)7, and the article carrier3or article carrier stack8is transported from the unloading device(s)65to the reloading device(s)32using the conveying system and is/are subsequently taken over from the fixed-installation conveying system by means of the reloading device(s)32and is/are transferred from it to the target loading aid(s)34.

In this regard, the fixed-installation conveying system is arranged between the unloading station with the at least one automatically operated unloading station65and the reloading station with the at least one automatically operated reloading device32(palletizing).

During the unloading operation using the relevant unloading device65, individual article carriers3or a partial article carrier stack (with articles of just one type) are removed from the article carrier stack8.

The article carriers3may be successively transferred onto the fixed-installation conveying system and be transported as separate article carriers3. In this regard, the article carriers3can advantageously be successively discharged onto the fixed-installation conveying system in a sequence provided by the packing order of the article carriers3at the target loading aid34and be transported to the at least one reloading device32successively in said order.

By contrast, article carriers3required for a picking order can also be stacked on the fixed-installation conveying system and pre-picked partial article carrier stacks8″ or article carrier stacks8′ can be transported from the unloading device65or the unloading devices65to the reloading device32or reloading devices32, as shown in an exemplary manner inFIG.7a. In this regard, the article carriers3can advantageously be discharged onto the fixed-installation conveying system in a sequence provided by the packing order of the article carriers3at the target loading aid34such that at least one (pre-picked) partial article carrier stack8″ or article carrier stack8′ is made up of multiple article carriers3arranged on top of one another and is then transported to the at least one reloading device32.

Said packing order may be determined by a computer and considers for example the stability of the article carrier3and/or the dimensions of the article carriers and/or the weight of the articles2/article carriers3. At the target loading aid34, heavy article carriers3are accommodated at the bottom of the stack while lightweight article carriers3are accommodated at the top of the stack. Containers are arranged at the bottom of the stack, cartons at the top of the stack. The control system47may comprise said computer.

Step ix) may comprise transporting loaded transport loading aids7using the autonomously moveable, driverless transport vehicles9from the storage zone5(but possibly also from the loading station in the delivery zone4) to an unloading station and directly providing (a) loaded loading aid(s)7on one or multiple automatically operated unloading device(s)65.

However, step ix) may also comprise transporting loaded transport loading aids7using the autonomously moveable, driverless transport vehicles9from the storage zone5(but possibly also from the loading station in the delivery zone4) to an unloading station onto a buffer surface66close to the unloading device(s)65and transporting said loaded transport loading aid(s)7using the autonomously moveable, driverless transport vehicles9to the unloading device(s)65and providing said loaded transport loading aid(s)7on one or multiple automatically operated unloading device(s)65.

Providing a loaded transport loading aid(s)7on one or multiple automatically operated loading device(s)65according to step ix) may comprise the following step:placing the loaded transport loading aid(s)7at a provisioning location67a,67bhaving the relevant unloading device65and having the transport vehicle9remain at the provisioning location67a,67bduring the unloading operation of the loaded transport loading aid(s)7according to step ix), orplacing the loaded transport loading aid(s)7at a provisioning location67a,67bhaving the relevant unloading device65and subsequently having the transport vehicle9move on from the provisioning location67a,67b, thus even before the start or during the unloading operation of the loaded transport loading aid(s)7according to step ix).

In the following, the method for storing and picking article carriers3that contain articles2and are stackable in the order fulfillment facility1c(third embodiment) is described.

The method comprises the steps i) to viii) as described above and the stepix) processing a picking order comprising the steps:transporting one or multiple transport loading aid(s)7containing the article carriers3required for a picking order from the storage zone5to an unloading station and providing said transport loading aid(s)7either at one or at multiple automatically operated unloading device(s)75or on a buffer surface66close the unloading device(s)75using one or multiple autonomously moveable, driverless transport vehicle(s)9,unloading one or multiple ones of the transport loading aid(s)7, which is (are) provided at the automatically operated unloading device(s)75, by removing the article carriers3required for processing the mentioned picking order, andassembling the article carrier3on one or multiple target loading aids34using of the unloading device(s)32for the mentioned picking order by performing the assembly of the article carriers3for the mentioned picking order such that the article carriers3removed from the article carrier stack8at the unloading device(s)75or the at least one or the article carrier stack(s)8removed at the unloading device(s)75is (are) transferred from the provided (first) transport loading aid(s)7to at least one mobile, empty (second) transport loading aid7comprising the transport loading aids7, and the at least one loaded (second) transport loading aid7kwith the article carrier3or (pre-picked) article carrier stack8′ is (are) transported from the unloading device(s)75to the reloading device(s)32using the autonomously moveable, driverless transport vehicle9and is/are subsequently taken over from the (second) transport loading aid(s)7using the reloading device(s)32and is/are transferred from it to the target loading aid(s)34.

The article carriers3required for a picking order can also be stacked on the (second) transport loading aid(s)7and the (second) transport loading aid(s)7with the pre-picked article carrier stack8′ can be transported from the unloading device75or the unloading devices75to the reloading device32or reloading devices32. In this regard, the article carriers3can advantageously be discharged onto the (second) transport loading aid(s)7in a sequence provided by the packing order of the article carriers3at the target loading aid34.

Said packing order may be determined by a computer and considers for example the stability of the article carrier3and/or the dimensions of the article carriers and/or the weight of the articles2/article carriers3. At the target loading aid34, heavy article carriers3are accommodated at the bottom of the stack while lightweight article carriers3are accommodated at the top of the stack. Containers are arranged at the bottom of the stack, cartons at the top of the stack. The control system47may comprise said computer.

Step ix) may comprise transporting loaded (first) transport loading aids7using the autonomously moveable, driverless transport vehicles9to an unloading station and directly providing (a) loaded (first) transport loading aid(s)7on one or multiple automatically operated loading device(s)75.

However, step ix) may also comprise transporting loaded (first) transport loading aids7using the autonomously moveable, driverless transport vehicles9to an unloading station onto a buffer surface76close to the unloading device(s)75and transporting said loaded (first) transport loading aid(s)7jusing the autonomously moveable, driverless transport vehicles9from the buffer surface76to the unloading device(s)75and providing said loaded transport loading aid(s)7on one or multiple automatically operated unloading device(s)75.

The transport vehicles9may also be controlled by the main computer such that they arrive at the unloading station in a sequence provided by the packing order of the article carriers3at the target loading aid34. Thus, a sequencing of the (second) transport loading aids7and/or article carrier stacks8′ is achieved.

Providing a loaded (first) transport loading aid(s)7on one or multiple automatically operated loading device(s)75according to step ix) may comprise the following step:placing the loaded (first) transport loading aid(s)7at a provisioning location77a,77bhaving the relevant unloading device75and having the transport vehicle9remain at the provisioning location77a,77bduring the unloading operation of the loaded (first) transport loading aid(s)7according to step ix), orplacing the loaded (first) transport loading aid(s)7at a provisioning location77a,77bhaving the relevant unloading device75and subsequently having the transport vehicle9move on from the provisioning location77a,77b, thus even before the start or during the unloading operation of the loaded (first) transport loading aid(s)7according to step ix).

Providing an empty (second) transport loading aid(s)7on one or multiple automatically operated loading device(s)75according to step ix) may comprise the following step:placing the empty (second) transport loading aid(s)7at a provisioning location77a,77bhaving the relevant unloading device75and having the transport vehicle9remain at the provisioning location77a,77bduring the loading operation of the empty (second) transport loading aid(s)7according to step ix), orplacing the empty (second) transport loading aid(s)7at a provisioning location77a,77bhaving the relevant unloading device75and subsequently having the transport vehicle9move on from the provisioning location77a,77b, thus even before the start or during the unloading operation of empty (second) transport loading aid(s)7according to step ix).

Providing an empty (second) transport loading aid(s)7on one or multiple automatically operated loading device(s)32according to step ix) may comprise the following step:placing the loaded (second) transport loading aid(s)7at a provisioning location40a. . .40bhaving the relevant unloading device32and having the transport vehicle9remain at the provisioning location40a. . .40bduring the unloading operation of the loaded (second) transport loading aid(s)7according to step ix), orplacing the loaded (second) transport loading aid(s)7at a provisioning location40a. . .40bhaving the relevant unloading device32and subsequently having the transport vehicle9move on from the provisioning location40a. . .40b, thus even before the start or during the unloading operation of the loaded (second) transport loading aid(s)7according to step ix).

The method for storing and picking articles2in the order fulfillment facility1ccan additionally comprise the following steps:acquiring picking orders on an order-processing computer46,determining the articles required for one of the picking orders (demand),analysis of a stock of those articles2which are required for the mentioned picking order, which picking order comprises one or multiple first article carrier(s)3containing the article(s)2and one or multiple second article carrier(s)3containing the article(s),assembling the article carriers3for the mentioned picking order in consecutive picking steps if a required quantity of an article2exceeds the stock of said article2, whereini) in a first picking step, the (second) transport loading aid7is loaded with one or multiple first article carrier(s)3at the unloading device75, and subsequently said (second) transport loading aid7is transported from the unloading device75to a buffer surface76using an autonomously moveable, driverless transport vehicle9and is buffered there, andii) in a second picking step, the (second) transport loading aid7is transported from the buffer surface76to the unloading device75using an autonomously moveable, driverless transport vehicle9and is provided there, if a required quantity of an article2falls below the stock of said article2, and subsequently the (second) transport loading aid7is loaded with one or multiple second article carriers3,transporting the (second) transport loading aid7from the unloading device75to the reloading device32using an autonomously moveable, driverless transport vehicle9after steps i) and ii) have been concluded, andtransferring the article carrier stack8,8′ onto a target loading aid34using the reloading device32.

The method for storing and picking articles2in the order fulfillment facility1a,1b,1ccan additionally comprise the step x):transporting a transport loading aid7from the unloading station back to the storage zone5after removing of the article carriers3, if not all article carriers3have been removed from the mentioned transport loading aid7, ortransporting a transport loading aid7from a first unloading device32;65;75to a second unloading device32;65;75after removing of the article carriers3, if not all article carriers3have been removed from the mentioned transport loading aid7and if said article carriers3are needed at the second unloading device32;65;75for a picking order, ortransporting a transport loading aid7from the unloading device32;65;75to a waiting zone37in the unloading station32;65;75after removing of the article carriers3, if not all article carriers3have been removed from the mentioned transport loading aid7and if said article carriers3are needed at the mentioned unloading device32;65;75or one of the unloading devices32;65;75for an already advised picking order, ortransporting an (empty) transport loading aid7back to the loading station after removing of the article carrier stack8,8′ and providing the transport loading aid7either at the automatically operated loading device13or on the buffer surface30, if all article carriers3have been removed from the mentioned transport loading aid7.

The method for storing and picking articles2in the order fulfillment facility1a,1b,1ccan additionally comprise the following steps:providing a cleaning system with an automatically operated cleaning robot90(as schematically depicted inFIG.1), andcleaning the transport loading aids7and/or the base in the loading station and/or unloading station (therefore the provisioning locations16a,16b,40a,40b,71a,71b,77a,77b, the buffer surface36,67,76and according to the first embodiment the waiting zone37) and storage surface31in the storage zone5with the cleaning robot90.

As depicted only inFIG.1and explained with the example of the first picking system1a, the method for storing and picking articles2may additionally comprise the following steps:providing a first temperature zone91ain the storage zone5, in which the transport loading aids7with the at least one article carrier stack8of article carriers3stacked on top of one another and containing articles2of a first article group,providing a second temperature zone91bin the storage zone5, in which the transport loading aids7with the at least one article carrier stack8of article carriers6stacked on top of one another and containing articles2of a second article group,definition of a first article group and of a second article group, to which first article group articles2of a first storage temperature are assigned and to which second article group articles2of a second storage temperature are assigned, and detecting data containing data on the first article group, in particular a first storage temperature for the articles2, and the second article group, in particular a second storage temperature for the articles2, on a computer (which is connected to the control system47),identifying the article carriers3and/or article carrier stacks8and/or transport loading aids7using a detection device (not depicted) provided in the delivery zone4by reading a data carrier92a,92b,92c(RFID, barcode) (only depicted inFIG.4b), which data carrier92a,92b,92cis affixed in each case on the article carriers3and/or article carrier stacks8and/or transport loading aids7,selectively transporting the (first) transport loading aids7, each loaded at the loading station in step v) with at least one article carrier stack8, using the autonomously moveable, driverless transport vehicles9either in the first temperature zone91aor second temperature zone91b,storing the (first) transport loading aids7with the at least one article carrier stack8of article carriers3stacked on top of one another and containing articles2of the first article group in the first temperature zone91a, andstoring the (first) transport loading aids7with the at least one article carrier stack8of article carriers3stacked on top of one another and containing articles2of the second article group in the second temperature zone91b.

The method for storing and picking articles2can additionally comprise the following steps:transporting one or multiple transport loading aid(s)7containing the article carriers3required for a first picking order from the first temperature zone91aand transporting one or multiple transport loading aid(s)7containing the article carriers3required for a second picking order from the second temperature zone91bto the unloading station using a shared, automatically operated unloading device32;65;75,providing the mentioned transport loading aid(s)7for the first picking order either at the automatically operated unloading device32;65;75or on a buffer surface36;66;76near the unloading device32;65;75using the autonomously moveable, driverless transport vehicle(s)9,providing the mentioned transport loading aid(s)7for the second picking order either at the automatically operated unloading device32;65;75or on a buffer surface36;66;76near the unloading device32;65;75using the autonomously moveable, driverless transport vehicle(s)9, andsequentially assembling article carrier stacks8on a first target loading aid34(outgoing article unit) with multiple article carrier stacks8of article carriers3stacked on top of one another and containing articles2of a first article group, and assembling article carrier stacks8on a second target loading aid34(outgoing article unit) with multiple article carrier stacks8of article carriers3stacked on top of one another and containing articles2of a second article group at the removal station with a shared, automatically operated removal device65;75and/or reloading station with a shared, automatically operated reloading device32.

FIGS.9aand9bshow a fourth embodiment of an order fulfillment facility1dfor storing and picking article carriers3that contain articles2(as only shown inFIG.11afor reasons of clarity) and are stackable.FIGS.10ato10dshow individual cutouts from the order fulfillment facility1d. The order fulfillment facility1dalso comprises a delivery zone4, a storage zone5, an order processing zone6, a plurality of transport loading aids107each for accommodating and stabilizing the position of at least one article carrier stack8and a plurality of autonomously moveable, driverless transport vehicles9for transporting transport loading aids107. The article carrier stack8is formed by multiple article carriers3arranged (stacked) on top of one another. Contrary to the first, second and third embodiment according toFIGS.1to8,8a, the order fulfillment facility1dadditionally comprises stack loading aids, as they are shown in more detail inFIGS.12ato12c, each for stabilizing the position of an order stack101made up of the article carriers3according to a picking order. It is noted that the first, second and third embodiment of the order fulfillment facility1a,1b,1cmay also comprise such stack loading aids.

The stack loading aids comprise either first stack loading aids100a(FIG.12a—shows an unloaded stack loading aid andFIG.12b—shows a loaded stack loading aid) or second stack loading aids100b(FIG.12c—shows an unloaded stack loading aid). It is also possible that the stack loading aids comprise both first stack loading aids100aand second stack loading aids100b.

In the order fulfillment facility1dshown inFIGS.9a,9b,10ato10d, stack loading aids, which comprise the first stack loading aids100a(seeFIG.12a), are used, which are loaded with the target loading aid34, for example a pallet.

If instead of the first stack loading aids100athe second stack loading aids100b(seeFIG.12c) is used in the order fulfillment facility1d, the second stack loading aid100bforms the target loading aid134. In this case, the lading station described in the following may be omitted.

Contrary to the above-mentioned embodiment, in which the first stack loading aid100ais equipped with the target loading aid34, this embodiment does not allow for an additional target loading aid34.

The transport loading aid107as shown in further detail inFIGS.11ato11calso proves advantageous.

As schematically depicted inFIG.9a, the order fulfillment facility1dlikewise comprises the order processing computer46for detecting picking orders and for determining articles2which are required for the picking order. In this regard, a picking order comprises one order line (for example six article carriers3with a first article2) or multiple order lines (for example three article carriers3with a first article2and three article carriers3with a second article2), as described above.

In the delivery zone4, the provision of article carrier stacks8is envisaged, as comprehensively described above. According to the embodiment shown, the article carrier stacks8are delivered to the delivery zone4on pallets (delivery load carrier) as an article carrier stack group10. In this case, an article carrier stack group10of a depalletizing station is supplied, in which article carrier stacks8of multiple article carriers3, arranged on top of one another, from one article carrier stack group10are separated. Such article carrier stack groups10are most times made up of article carrier stacks8containing articles of just one type.

FIGS.9aand10ashow a possible embodiment, in which a depalletizing station with at least one automatically operated depalletizing device11(schematically adumbrated), a first conveying device112afollowing the depalletizing device11for supplying article carrier stack groups10(incoming article units), a second conveying device112bfollowing the depalletizing device11for transporting delivery load carriers away, a loading station with at least one automatically operated first loading device113(schematically adumbrated), a third conveying device114aconnecting, in respect of a conveying stream, the depalletizing device11to the first loading station113for supplying article carrier stacks8and/or a fourth conveying device114bconnecting, in respect of a conveying stream, the depalletizing device11to the loading station113for supplying article carrier stacks8may be provided in the delivery zone4. The fourth conveying device114bfor supplying article carrier stacks8is optional and may also be omitted.

As not shown in further detail, a rotating device may be provided between the depalletizing device11and the loading device113, which rotating device rotates the article carrier stacks8by 90°, so that the article carrier stacks8are always provided in the same orientation at the loading device113, regardless of how the article carrier stacks8and/or article carriers3are delivered.

The article carrier stacks8are provided “unamendedly” in a transfer position at the loading device113. The transfer location15ais preferably formed on the third conveying device114a.

As described in the following, the loading station comprises one or multiple automatically operated first loading device(s)113(schematically adumbrated).

The schematically shown first loading device113comprises at least one first provisioning location16afor the first transport loading aid107aand a transfer device117for transferring a second article carrier stack8bfrom the first transfer location15aonto the first transport loading aid107a. The first provisioning location16aand the first transfer location15aare arranged so as to be located opposite one another.

It also proves advantageous if the loading station has at least one separate buffer surface30near the first loading device113or near each first loading device113. Preferably, the first loading device113is assigned one buffer surface30per provisioning location16a. However, in principle, the loading station may also comprise only one buffer surface30. The buffer surface30is preferably formed on a base of the order fulfillment facility1d.

In concrete terms, the automatically operated loading device113comprises a transfer device117that is movable relative to the transfer location15a, in order to move an article carrier stack8b(or possibly individual article carriers3) provided in a transfer position at the transfer location15ato the transport loading aid107a. The transfer device117can be formed for example by a pusher actuatable by an actuating drive. The transfer device117is arranged above the conveying device114a.

According to a first embodiment, the loading device113may specifically comprise a gantry robot. Gantry robots are understood to be industrial robots, which in their base axes are constructed from linear axles. Using a line gantry is sufficient for loading.

The gantry robot comprises vertical uprights and a longitudinal beam, which are connected to one another, forming a support construction118. Additionally, the gantry robot comprises a gantry slide119, that is movable in a first direction (x-direction-horizontal movement) along a guide assembly via a first drive device (not depicted), and a gantry arm120arranged on the gantry slide119. A transfer device117is arranged on the gantry arm120.

It may prove useful if the gantry arm120is also movable in a second direction (z-direction-vertical movement) along a guide assembly via a second drive device.

InFIGS.9a,10a, the first article carrier stack8ahas already been discharged onto the first transport loading aid107a, while the second article carrier stack8bis still at the transfer location15a. In the course of the pushing movement, the article carrier stack8bis moved from the transfer location15ato the first transport loading aid107awhich is provided at the first provisioning location16a.

As described above, the first transfer location15a, second transfer location15b, first provisioning location16aand the second provisioning location16bmay be provided on this loading device113as well.

Even though, in the depicted embodiment, the loading station is shown having a single first loading device113for reasons of clarity, the number of first loading devices113may vary depending on the required picking performance, as already described above regarding the embodiments.

According to an embodiment that is not shown, the loading device113may comprise a jointed-arm robot, as described above regarding the loading device13.

As depicted inFIG.9a, an empty (first) transport loading aid107bmay be transported to the provisioning location16a(16b) using an autonomously moveable, driverless transport vehicle9and be placed there. While loading the (first) transport loading aid107a, said transport vehicle9may be used for other transport purposes. However, in principle, it is also possible that the autonomously moveable, driverless transport vehicle9is transported to the provisioning location16a(16b) and placed there but remains at the provisioning location16a(16b) while the (first) transport loading aid107ais loaded. If a (first) transport loading aid107ais already placed at the provisioning location16aor if the (first) transport loading aid107ais currently being loaded, the empty (first) transport loading aid107bcan be buffered on the buffer surface30provided near the loading device113.

After being loaded (with at least one article carrier stack8), a (first) transport loading aid107cis transported from the loading station, in particular from the first loading station113, or from the first loading devices113to the storage zone5using an autonomously moveable, driverless transport vehicle9and is placed on the storage area31in the storage zone5.

As evident inFIGS.9band10b, an unloading station with at least one automatically operated unloading device132(schematically adumbrated) is arranged in the order processing zone6. According to this embodiment, the unloading station with the automatically operated unloading device132or the multiple automatically operated unloading devices132simultaneously forms a reloading station with the one automatically operated reloading device (palletizing device) or the multiple automatically operated reloading devices (palletizing devices), by means of which the article carriers3or article carrier stacks8are transferred from the transport loading aid107onto the target loading aid34. Therefore, the term “unloading device” may be used synonymously with “reloading device”.

As described in the following, the unloading station comprises the at least one automatically operated unloading device132(schematically adumbrated). Even though, in the depicted embodiment, the unloading station is shown having a single unloading device132for reasons of clarity, the number of unloading devices132may vary depending on the required picking performance. For example, the unloading station and/or the order fulfillment facility1dmay have a second unloading device132, third unloading device132etc. These unloading devices132are preferably constructed identically.

The schematically shown embodiment of the automatically operated unloading device132comprises a first provisioning location40afor the loaded first transport loading aid107e, an (optional) second provisioning location40bfor the loaded second transport loading aid107eand a transfer device147movable relative to the provisioning location40a. . .40bfor unloading the transport loading aid107eprovided at the provisioning location40a. . .40b. If the unloading station has more than one automatically operated unloading device132, each unloading device132comprises a first provisioning location40afor the loaded first transport loading aid107e, an (optional) second provisioning location40bfor the loaded second transport loading aid107eand a transfer device147movable relative to the provisioning location40a. . .40bfor unloading the transport loading aid107eprovided at the provisioning location40a,40b.

The transfer device147may for example be formed by a gripping system as it is described in detail inFIGS.13ato13d,14a,14b,15ato15nand16ato16n.

It also proves advantageous if the unloading station has at least one separate buffer surface36near the unloading device132or near each unloading device132. In the depicted embodiment, the unloading device132is assigned one buffer surface36per provisioning location40a. . .40b. However, in principle, the unloading station may also comprise only one buffer surface36. The buffer surface36is preferably formed on a base of the order fulfillment facility1d. This way, it is possible that the loaded (first) transport loading aid(s)107dare buffered on the buffer surface36, near the unloading device(s)132, and are transported as needed to the respective provisioning location40a. . .40bof the unloading device(s)132over a short distance using the transport vehicles9.

The unloading station may also have one or multiple waiting zone(s)37(not depicted), as described above in detail.

According to a first embodiment, the unloading device132may specifically comprise a gantry robot. Gantry robots are understood to be industrial robots, which in their base axes are constructed from linear axles. An area gantry is used for loading.

The gantry robot comprisesi) vertical uprights, longitudinal beams and transverse beams, which are connected to one another, forming a support construction142,ii) a first gantry slide143mounted on the support structure142and horizontally movable in a first direction (x-direction) along a guide assembly (which is arranged on one of the longitudinal beams) via a first drive device,iii) a gantry arm144affixed to the first gantry slide143and movable therewith in the first direction (x-direction),iv) a second gantry slide145mounted on the gantry arm144and vertically movable in a second direction (z-direction) along a guide assembly via a second drive device,v) a third gantry slide146arranged on the second gantry slide145and horizontally movable in a third direction (y-direction) along a guide assembly via a third drive device, andvi) the transfer device147, which is arranged on the third gantry slide146and is mounted on the third gantry slide146so as to be rotatable about a vertical axis.

During the unloading movement, the article carrier3, partial article carrier stack or article carrier stack8is picked up by the transfer device147and/or the gripping system from the transport loading aid107e, which is provided at the provisioning location40a. . .40b, and subsequently transferred onto a target loading aid34according to the shown embodiment with the first stack loading aid100a. If the order fulfillment facility1dcomprises the second stack loading aids100a, the article carrier3, partial article carrier stack or article carrier stack8is picked up by the gripping system from the transport loading aid107e, which is provided at the provisioning location40a. . .40b, and subsequently transferred onto the target loading aid134.

The shown gantry robot proves advantageous if the available ceiling height is low.

According to an embodiment, which is not depicted, the unloading device132(reloading device) may comprise a jointed-arm robot, as described above.

The schematically shown embodiment of the automatically operated unloading device132comprises a provisioning location139afor a first stack loading aid100a(or second stack loading aid100b) or multiple provisioning locations139a. . .139bfor first stack loading aids100a(or second stack loading aids100b) and the transfer device147that is movable relative to the provisioning location139a. . .139bfor loading the transport loading aid34,134provided at the provisioning location139a. . .139b.

If the unloading station has more than one automatically operated unloading device132, each unloading device132comprises a provisioning location139afor a target loading aid34,134or multiple provisioning locations139a. . .139bfor target loading aids34,134and the transfer device147that is movable relative to the provisioning location139a. . .139bfor loading the transport loading aid34,134provided at the provisioning location139a. . .139b.

As described above, the (additional) target loading aid34with the first stack loading aid100amay be provided at the provisioning location139a. . .139bor the target loading aid134(which is formed by the second stack loading aid100b) may be provided at the provisioning location139a. . .139b.

It also proves advantageous if the unloading station has at least one separate buffer surface136near the unloading device132or near each unloading device132. In the depicted embodiment, the unloading device132is assigned one buffer surface136per provisioning location139a. . .139b. However, in principle, the unloading station may also comprise only one buffer surface136. The buffer surface136is preferably formed on a base of the order fulfillment facility1d. This way, it is possible that the empty target loading aids34with the first stack loading aid100aand the target loading aid134with the second stack loading aid100bare buffered on the buffer surface136, near the unloading device(s)132, and are transported as needed to the respective provisioning location139a. . .139bof the unloading device(s)132over a short distance using the transport vehicles9.

According to the shown embodiment, the target loading aids34with the first stack loading aid100aand the target loading aid134with the second stack loading aid100bare transported to the respective provisioning location139a. . .139bof the unloading device(s)132and are transported away from the respective provisioning location139a. . .139bof the unloading device(s)132using the transport vehicles9. The above-described fixed-installation first conveying system33for transporting completely loaded target loading aids away and the fixed-installation second conveying system35for supplying empty target loading aids are not provided according to this embodiment.

Autonomously moveable, driverless transport vehicles9(of a driverless transport system), which are automatically controlled by the superordinate main computer, are used for transporting the empty transport loading aids107and the transport loading aids107loaded with article carrier stacks as well as the empty target loading aids34with the first stack loading aid100aand the empty target loading aids134with the second stack loading aid100band target loading aids with the first stack loading aid100aloaded with the order stacks101and the loaded target loading aids134with the second stack loading aid100b. The control system47may comprise said main computer.

As evident inFIGS.9band10c, the unloading station may additionally comprise one or multiple unloading device(s)151(schematically adumbrated) operated in a semi-automated manner, on which the article carriers3or article carrier stacks8are transferred from a third transport loading aid150onto one or multiple target loading aids34,134. It is possible for only one single unloading device151to be provided at which the article carriers3or article carrier stacks8are transferred from a third transport loading aid150onto one or multiple target loading aids34,134. The number of unloading devices151may vary depending on the required picking performance. These unloading devices151are preferably constructed identically.

At the unloading device(s)151, article carriers3are picked, which cannot be automatically picked at the unloading device(s)132because the base surfaces of the article carriers are smaller than 300 mm×400 mm or the article carriers3have a dimensional stability that is too low to be manipulated automatically.

The unloading device(s)151operated in a semi-automated manner each comprise a first provisioning location152afor a third transport loading aid150, a second provisioning location152bfor a first stack loading aid100a(or second stack loading aid100b) and a working area155for a picker (not depicted for reasons of clarity). The working area155may also comprise a working surface156with wheels and the like in order to make an ergonomic manipulation of the article carriers3possible. The first provisioning location152aand the second provisioning location152bare arranged so as to be located opposite one another. Additionally, the unloading device151may comprise an input and/or output device (not depicted), by means of which picking instructions for the picker are output and at which picking commands are entered by the picker.

As described above, the (additional) target loading aid34with the first stack loading aid100amay be provided at the provisioning location152or the target loading aid134(which is formed by the second stack loading aid100b) may be provided at the provisioning location152b.

It should be noted here that the unloading device(s)151operated in a semi-automated manner may also be used in the order fulfillment facilities1a. . .1c(without additional stack loading aids) described above. In this case, the third transport loading aids150are provided at the first provisioning location152aand the target loading aids34(without stack loading aids) are provided at the second provisioning location152b.

While according to the above-described embodiments, an automated picking operation takes place at the unloading devices32;65;75;132, a manual picking operation is performed at the unloading device(s)151.

In the mentioned context, “semi-automated” means that transporting third transport loading aids150(or the first/second transport loading aids7) to the unloading device151, transporting third transport loading aids150away from the unloading device151, transporting first stack loading aids100a(or second stack loading aid100bor the target loading aids34) to the unloading device151, transporting first stack loading aids100a(or second stack loading aid100bor the target loading aids34) away from the unloading device151is performed automatically and picking is performed manually by a picker.

The third transport loading aid150is transported to the first provisioning location152ausing the transport vehicle9and transferred to said provisioning location152aso as to provide the third transport loading aid150at the provisioning location152a, or transferred from the first provisioning location152aonto the transport vehicle9so as to transport the third transport loading aid150away from the provisioning location152a.

Likewise, the first stack loading aid100a(or second stack loading aid100bor the target loading aid34) is transported by the transport vehicle9to the second provisioning location152band transferred onto it so as to provide the first stack loading aid100a(or second stack loading aid100bor the target loading aid34) at the provisioning location152b, it is transferred from the second provisioning location152bonto the transport vehicle9so as to transport the first stack loading aid100a(or second stack loading aid100bor the target loading aid34) away from the provisioning location152b.

It also proves advantageous if the unloading station has at least one separate buffer surface153afor the third transport loading aid150and at least one separate buffer surface153bfor the first stack loading aid100a(or second stack loading aid100bor the target loading aid34) near the unloading device151or neat each unloading device151. In the depicted embodiment, the unloading device132is assigned one buffer surface153aper provisioning location152aor one buffer surface153bper provisioning location152b. However, in principle, the unloading station may also comprise only one buffer surface153aor buffer surface153b. The buffer surface153a,153bis preferably formed on a base of the order fulfillment facility1d. This way, it is possible that the loaded (third) transport loading aid(s)150and the first stack loading aid100a(the second stack loading aid100bor the target loading aid34) are buffered on the buffer surface153a,153b, near the unloading device(s)151, and are transported as needed to the respective provisioning location153a,153bof the unloading device(s)151over a short distance using the transport vehicles9.

According to the depicted embodiment, the first provisioning location152ais formed on a lifting platform154a, on which the third transport loading aid150is placed and the article carrier stack8can be lifted to a provisioning level in order to make ergonomic working possible, and the second provisioning location152bis formed on a lifting platform154b, on which the first stack loading aid100a(or second stack loading aid100bor the target loading aid34) can be placed and the target loading aid34,134(of the target loading aid34,134is not loaded yet) or an order stack101(if the target loading aid34,134has already been loaded using one or multiple automatically operated loading device(s)132) can be lifted to a provisioning level in order to make ergonomic working possible.

FIGS.9aand10dshow a loading station for loading third transport loading aids150, which loading station comprises one or multiple automatically operated second loading device(s)160(schematically adumbrated). The order fulfillment facility1dcomprises this loading station. The second loading device160comprises a provisioning location161for an empty (third) transport loading aid150and a transfer device162for loading the transport loading aid150provided on the provisioning location161, which transfer device162is movable relative to the provisioning location161.

It also proves advantageous if the loading station has at least one separate buffer surface163near the second loading device160or near each second loading device160. In the depicted embodiment, the second loading device160is assigned one buffer surface163per provisioning location161. However, in principle, the loading station may also comprise only one buffer surface160. The buffer surface160is preferably formed on a base of the order fulfillment facility1d.

As evident from the figures, the third transport loading aid150may be different from the aforementioned transport loading aids7,107. However, this is not imperatively necessary.

The third transport loading aids150are loaded in the delivery zone4at the loading station using an automatically operated second loading device160(schematically adumbrated). Preferably, the article carrier stack group10with the pallet (delivery load carrier) is transferred onto the third transport loading aid150unamendedly at the second loading device160, as evident inFIGS.9a,10d. Thus, no depalletizing operation takes place before. Such article carrier stack groups10are most times made up of article carrier stacks8containing articles of just one type. According to the embodiment shown, the article carrier stacks8are delivered to the delivery zone4on pallets (delivery load carrier) as an article carrier stack group10and the conveying device112bconveys them to the loading device160.

An empty (third) transport loading aid150is transported to the loading station using an autonomously moveable, driverless transport vehicle9and provided at the second loading device160or on a buffer surface163. After being loaded (with the article carrier stack group10), the (third) transport loading aid150is transported from the loading station, in particular from the first second loading device160, to the storage zone5using the autonomously moveable, driverless transport vehicles9and is placed on a storage area31in the storage zone5.

FIGS.9aand10dalso show a lading station with one or multiple automatically operated lading device(s)170, which the order fulfillment facility1dmay comprise and which make lading the first stack loading aid100awith a target loading aid34possible as long as a first stack loading aid100ais used in the order fulfillment facility1d. The target loading aid34is placed on the base (FIG.12a) of the first stack loading aid100a.

The lading device(s)170each comprise a provisioning location171for an empty first stack loading aid100aand a transfer device172for loading the stack loading aid100aprovided on the provisioning location171, which transfer device172is movable relative to the provisioning location171.

It also proves advantageous if the lading station has at least one separate buffer surface173near the lading device170or near each lading device170. In the depicted embodiment, the lading device170is assigned one buffer surface173per provisioning location171. However, in principle, the lading station may also comprise only one buffer surface173. The buffer surface173is preferably formed on a base of the order fulfillment facility1d.

An empty first stack loading aid100ais transported to the lading station using an autonomously moveable, driverless transport vehicle9and provided at the lading device170or on a buffer surface173. After being laded with a target loading aid34, the stack loading aid100ais transported from the lading station, in particular from the lading device170, to the unloading station (reloading station) using an autonomously moveable, driverless transport vehicle9.

FIGS.9aand10dalso show an order stack load securing station with one or multiple automatically operated load securing device(s)180, which the order fulfillment facility1dmay comprise and which makes securing the load of an order stack101with a securing means181possible.

The load securing device(s)180each comprise a provisioning location182for a loaded first stack loading aid100a(or a loaded second stack loading aid100b), a target loading aid lifting device and a securing means wrapping tool or a securing means strapping tool. The target loading aid lifting device comprises a vertically adjustable lifting frame183and telescopic forks184mounted thereon, the latter being movable between a retracted initial position and a protruding receiving position.

It should be noted that in the receiving position, the telescopic forks184, on the one hand, receive the target loading aid34together with the order stack101if no stack loading aids are used, as shown inFIG.1, or, if the first stack loading aid100ais used, as shown inFIG.12a, and on the other hand, only the order stack101if the second stack loading aid100bis used, as shown inFIG.12c, wherein the target loading aid34together with the order stack101or the order stack101may be lifted/lowered with a lifting movement of the lifting frame183.

It also proves advantageous if the order stack load securing station has at least one separate buffer surface185near the load securing device180or near each load securing device180. In the depicted embodiment, the load securing device180is assigned one buffer surface185per provisioning location182. However, in principle, the order stack load securing station may also comprise only one buffer surface185. The buffer surface185is preferably formed on a base of the order fulfillment facility1d.

According to the embodiment shown, the load securing device180comprises a wrapping tool, which wraps a thermoplastic film in a force-fit manner in the circumferential direction around the order stack101while the order stack101is lifted from the first stack loading aid100aor the second stack loading aid100busing the target loading aid lifting device. The thermoplastic film constitutes the securing means181.

In the alternative, a strapping tool may also be used in the load securing device180, which is configured to fasten at least one sealing strap in a substantially horizontal direction circumferentially at the order stack101while the order stack101is in the load securing device180. The sealing strap constitutes the securing means181.

A loaded first stack loading aid100a(or second stack loading aid100b) is transported to the order stack load securing station using an autonomously moveable, driverless transport vehicle9and provided at the load securing device180or on a buffer surface185.

After the order stack101has been removed from the first stack loading aid100a, the empty first stack loading aid100amay be transported using an autonomously moveable, driverless transport vehicle9from the order stack load securing station, in particular from the load securing device180to the lading station.

If the stack loading aids comprise the second stack loading aid100b, after the order stack101has been removed from the second stack loading aid100b, the empty second stack loading aid100bmay be transported using an autonomously moveable, driverless transport vehicle9from the order stack load securing station, in particular from the load securing device180to the unloading station.

It should be noted that also the first, second and third embodiment of the order fulfillment facility1a,1b,1cmay comprise the automatically operated second loading device(s), the optional lading station, and the order stack load securing station.

InFIGS.11ato11c, a fourth embodiment of a transport loading aid107.FIG.11ashows the unloaded, empty transport loading aid107andFIG.11bshows the loaded transport loading aid107. Such a transport loading aid107may also, by a short “offset motion”, provide multiple article carrier stacks8consecutively at the provisioning locations described above. The “offset motion” is preferably performed by a transport vehicle9. Such a transport loading aid107can also provide multiple article carrier stacks8consecutively at the provisioning locations by a “rotating motion” about the vertical axis. The “rotating motion” is preferably performed by a transport vehicle9.

The transport loading aid107again comprises the base55and side walls56a,56b,56c,56dconnected thereto, each for the stabilization of the position of article carrier stacks8and a first loading and unloading opening57aand second loading and unloading opening57dlocated opposite the side wall56con a first side, and a third loading and unloading opening57cand fourth loading and unloading opening57dlocated opposite the side wall56con a second side.

The side walls56a,56b,56c,56dare preferably designed essentially at the height of the article carrier stack8, however at least at a sufficient height for the topmost article carrier3in the article carrier stack8to be surrounded by the side walls56a,56b,56c,56dat least in some regions. Preferably, the first/second/third/fourth loading and unloading opening57a,57b,57c,57deach extend over the entire height of the side walls56a,56b,56c,56d.

It is advantageous if the depth of the one accommodating shaft or the multiple accommodating shafts, which is/are limited between the first side walls56a,56b,56d, is smaller than a minimum width of the article carriers3, so that the article carriers3always protrude at the front edge of the first side walls56a,56b,56dif the article carriers3are mounted in the corresponding accommodating shaft, as can be seen inFIG.11band, for example, inFIG.15atoFIG.15forFIG.16atoFIG.16k. This way, a reliable clamping and gripping function is enabled.

The transport loading aid107may comprise outer first side walls56a,56brunning in parallel to one another and a parallel inner side wall56d. The second side wall56cextends between the first side walls56a,56b,56d. The inner first side wall56dis arranged in the center region of the base55such that the side walls56a,56b,56c,56ddelimit two accommodating shafts on a first side relative to the side wall56c, and two accommodating shafts on a second side relative to the side wall56c.

In each accommodating shaft, at least one article carrier stack8can be accommodated for transport/for storage. In the depicted embodiment, one article carrier stack8with a base area of the article carriers of 600 mm×400 mm is accommodated in the first accommodation shaft, and two article carrier stacks8each with a base area of the article carriers of 300 mm×400 mm are accommodated in the third and fourth accommodation shafts. This transport loading aid107can transport multiple article carrier stacks8simultaneously.

It proves to be advantageous if the outer first side walls56a,56band possibly also the inner first side wall56dare configured having lead-in chamfers (not depicted) for enabling easy loading and/or unloading of the transport loading aid107.

As can be particularly seen inFIG.11c, the second side wall56cmay comprise a first side wall part200aand a second side wall part200b. The first side wall part200ais inclined at an inclination angle towards a vertical plane spanned between the first side walls56a,56b,56dsuch that the first side wall part200ais inclined backwards with increasing vertical distance from the base55. The second side wall part200bis inclined at an inclination angle towards a vertical plane spanned between the first side walls56a,56b,56dsuch that the second side wall part200bis inclined backwards with increasing vertical distance from the base55.

The inclination angle α1is between 2° and 5°.

As can also be seen inFIG.11c, the base55also comprises a first base part201aand a second base part201b. The first base part201ais inclined downwards in the direction of the second side wall56cat an inclination angle towards a horizontal plane spanned between the first side walls56a,56b,56d. The second base part201bis inclined downwards in the direction of the second side wall56cat an inclination angle towards a horizontal plane spanned between the first side walls56a,56b,56d.

The inclination angle α2is preferably larger than the inclination angle α1and amounts to between 3° and 6°.

The base55on its upper side again forms a placing surface58, on which the article carrier stacks8can be placed, and on its bottom side a transport surface59, against which the loading platform51of the transport vehicle9can be placed. In concrete terms, the placing surface58is formed on the base wall parts201a,201b.

Additionally, the transport loading aid107may comprise adjustable feet60which are affixed to the base55. The transport loading aid107is placed via the adjustable feet60on the base. In an embodiment that is not shown, wheels instead of adjustable feet60may also be provided on the base55.

At this point, it should also be noted that the transport loading aid107may also be configured according to the embodiments described above and that the side walls56a,56b,56dare arranged accordingly and one single accommodation shaft may be arranged between them (FIG.4a,4b) or accommodation shafts separated by the side wall56c(FIG.5a,5b) or accommodation shafts separated by the side wall56d(FIG.6a,6b).

It should further be noted at this point that the transport loading aid7,7′,7″ may also be configured according to the embodiment described inFIGS.11ato11cand that the side wall56ccomprises a first side wall part200a, which is inclined at an inclination angle towards a vertical plane spanned between the first side walls56a,56bor56a,56b,56dsuch that the first side wall part200ais inclined backwards with increasing vertical distance from the base55.

Likewise, the base55may comprise a first base part201a, which is inclined downwards in the direction towards the second side wall56cat an inclination angle towards a horizontal plane spanned between the first side walls56a,56bor56a,56b,56d.

As described above, the order fulfillment facility1a,1b,1c,1dmay comprise one or multiple stack loading aids, each for stabilizing the position of an order stack101assembled of the article carriers3according to a picking order.

InFIGS.12aand12b, the first stack loading aid100ais shown, and inFIG.12c, the second stack loading aid100bis shown.

The first stack loading aid100acomprises a base205and stack walls206a,206bconnected thereto. Preferably, a first stack wall206aand a second stack wall206bare provided, which protrude perpendicularly at the base205and include a right angle.

The base205can comprise a placing surface207on its upper side, on which a target loading aid34can be placed with the order stack101, and a transport surface208on its lower side, against which a loading platform of the transport vehicle9can be placed.

The second stack loading aid100blikewise comprises a base205and stack walls206a,206bconnected thereto. Preferably, a first stack wall206aand a second stack wall206bare provided, which protrude perpendicularly at the base205and include a right angle.

As opposed to the first stack loading aid100a, the base comprises on its upper side protruding placing blocks211, which are separated from another by receiving channels210, on which placing blocks the article carriers3of the order stack101(not shown) may be placed, such that the at least one second stack loading aid100bforms the target loading aid134.

In addition, the base205comprises on its lower side a transport surface208, against which a loading platform of the transport vehicle9may be placed.

Even if only the first stack wall206aand the second stack wall206bare provided, sufficient stabilization of the position and safe transport of the order stack101is enabled using the first stack loading aid100aand the second loading aid100b. Moreover, the load securing device180may be operated with high performance as the first/second stack loading aid100a,100bmay already be transported away from the load securing device180as soon as the target loading aid34with the order stack101has been slightly lifted from the base205of the first stack loading aid100a, or the order stack101has been slightly lifted from the base205of the second stack loading aid100b. Therefore, it is not necessary to lift the order stack101completely and over the entire height of the first/second stack loading aid100a,100bbefore the first/second stack loading aid100a,100bmay be transported away.

Additionally, the first stack loading aid100a/the second stack loading aid100bmay comprise adjustable feet212, which are affixed to the base205. The first stack loading aid100a/second stack loading aid100bis placed on the base via the adjustable feet212. In an embodiment that is not shown, wheels instead of adjustable feet212may also be provided on the base55.

As not explained in detail, the transport loading aid107may also be provided with a data carrier92a, as described above. Likewise, the first stack loading aid100a/the second loading aid100bmay be provided with a data carrier for identifying the first stack loading aid100a/the second stack loading aid100busing a detection device by reading a data carrier.

The method described above for storing and picking articles2in the order fulfillment facility1a,1b,1c,1dmay additionally comprise the following step:providing stack loading aids100a,100b, each for stabilizing the position of an order stack101assembled of the article carriers3according to a picking order.

Providing the stack loading aids in the order fulfillment facility1a,1b,1c,1dmay comprise providing one or multiple first stack loading aid(s)100aand/or one or multiple second stack loading aid(s)100b.

If the first stack loading aids100aare used in the order fulfillment facility1a,1b,1c,1d, the method may additionally comprise the following step:lading the first stack loading aid100awith a target loading aid34at the lading station using one or multiple automatically operated lading device(s)170by placing the target loading aid34on the base205.

If the second stack loading aids100bare used in the order fulfillment facility1a,1b,1c,1d, the method may additionally comprise the following step:defining the second stack loading aid100bas the target loading aid134by the second stack loading aids100bforming the target loading aids134.

If the first stack loading aids100aand the second stack loading aids100bare used in the order fulfillment facility1a,1b,1c,1d, the method may additionally comprise the following steps:lading the first stack loading aid100awith a target loading aid34at the lading station using one or multiple automatically operated lading device(s)170by placing the target loading aid34on the base205, anddefining the second loading aid100bas the target loading aid134.

The method described above for storing and picking articles2in the order fulfillment facility1a,1b,1c,1dmay additionally comprise the following steps:providing one or multiple automatically operated second loading device(s)160,providing an article carrier stack group10of multiple article carrier stacks8arranged next to one another with article carriers3arranged on top of one another in the delivery zone4of the order fulfillment facility1a,1b,1c,1d,providing empty (third) transport loading aids150each for receiving and stabilizing the position of an article carrier stack group10,transporting empty (third) transport loading aids150using the autonomously moveable, driverless transport vehicles9to the loading station and providing one or multiple empty (third) transport loading aid(s)150either on one or on multiple automatically operated second loading device(s)160or on a buffer surface163close to the second loading device(s)160,loading one of the empty (third) transport loading aids160, which is provided at the automatically operated second loading device160, with at least one article carrier stack group10from the delivery zone4using the automatically operated second loading device160,transporting of the (third) transport loading aid150loaded with the article carrier stack group10from the loading station to the storage zone5using the autonomously moveable, driverless transport vehicle9,placing the (third) transport loading aid150loaded with at least one article carrier stack8on the storage surface31in the storage zone5, andstoring the (third) transport loading aid150loaded with the article carrier stack group10in the storage zone5.

The method may further comprise the following step(s):transporting empty target loading aids34;134using the autonomously moveable, driverless transport vehicles9to the unloading station and providing said empty target loading aids34;134either at one or at multiple semi-automated unloading device(s)151or on a buffer surface152bclose the unloading device(s)151using one or multiple autonomously moveable, driverless transport vehicle(s)9, and/ortransporting partially loaded target loading aids34;134using the autonomously moveable, driverless transport vehicles9from the automatically operated unloading device32;65;75;132to the semi-automated unloading device151or to a buffer surface152bclose to the semi-automated unloading device(s)151after the article carriers3have been assembled on the partially loaded target loading aid34;134at the automatically operated unloading device32;65;75;132and if article carriers3are still required for the mentioned picking order which are provided via the (third) target loading aids150at the semi-automated unloading device(s)151.

Processing a picking order that requires article carriers3from the (third) transport loading aid150may comprise the following steps:transporting one or multiple (third) transport loading aid(s)150containing the article carriers3required for the picking order from the storage zone5to the unloading station and providing said (third) transport loading aid(s)150either at one or at multiple semi-automated unloading device(s)151or on a buffer surface153aclose the unloading device(s)151using one or multiple autonomously moveable, driverless transport vehicle(s)9,manually unloading one or multiple ones of the (third) transport loading aid(s)150, which is/(are) provided at the semi-automated unloading device(s)151, by removing the article carriers3required for processing the mentioned picking order by a picker, andmanually assembling the article carriers3on one or multiple (empty or partially loaded) target loading aids34,134for the mentioned picking order by a picker if the target loading aid(s)34,134is/(are) provided at the semi-automated unloading device(s)151.

Assembling the article carriers3may comprise the following step:assembling the article carriers3according to the mentioned picking order to the order stack101on the target loading aid34in the first stack loading aid100aor on the base205of the second stack loading aid100b, said first stack loading aid100aor second stack loading aid100bbeing provided at the semi-automated unloading device(s)151.

The method described above for storing and picking articles2in the order fulfillment facility1a,1b,1c,1dmay additionally comprise the following steps:providing an order stack load securing station either with one or multiple automatically operated load securing device(s)180or with one or multiple automatically operated load securing device(s)180and a buffer surface185close to the load securing device(s)180, said load securing devices180being formed for secure transport of an order stack101with a securing means181,transporting stack loading aids100a,100beach loaded with one order stack101using the autonomously moveable, driverless transport vehicles9to the mentioned order stack load securing station and providing one or multiple stack loading aid(s)100a,100beither on one or on multiple automatically operated load securing device(s)180or on a buffer surface185close to the load securing device(s)180,removing the order stack101from the stack loading aid100a,100busing a lifting device (lifting frame183and telescopic forks184), by means of which the target loading aid34with the order stack101is lifted from the first stack loading aid100a, if the order fulfillment facility1a;1b;1c;1dcomprises the first stack loading aid100a, or by means of which the order stack101is lifted from the second stack loading aid100bif the order fulfillment facility1a;1b;1c;1dcomprises the second stack loading aid100b,securing the order stack101with the securing means181using the automatically operated load securing device180, in that the securing means181is placed circumferentially around the order stack101, andtransporting the secured order stack101, in particular using the autonomously moveable, driverless transport vehicles9, from the load securing station to a dispatch zone.

According to the first embodiment, the target loading aid34with the order stack101is lifted relative to the first stack loading aid100a, and the order stack101lifted from the first stack loading aid100ais simultaneously wrapped with the securing means181for stabilization. Subsequently, the secured order stack101is lowered again by the lifting device and transferred to a stationary conveying system (not shown) or to an autonomously moveable, driverless transport vehicle9. The order stack101now secured may be transported from the load securing station to a dispatch zone (consolidation area or article issue area). In this case, the target loading aid34forms the distribution load carrier.

According to the second embodiment, the order stack101is lifted relative to the second stack loading aid100a, and the order stack101lifted from the second stack loading aid100ais simultaneously wrapped with the securing means181for stabilization. Subsequently, the secured order stack101is lowered again by the lifting device and transferred to a distribution load carrier, preferably a roll container, a pallet and the like. The distribution load carrier is transported using a stationary conveying system (not shown) or an autonomously moveable, driverless transport vehicle9from the load securing station to a dispatch zone (consolidation area or article issue area).

Transporting the unloaded stack loading aids100a,100busing the autonomously moveable, driverless transport vehicles9comprises the following step(s):transporting the first stack loading aid100afrom the load securing station to the lading station with one or multiple automatically operated lading device(s)170, if a first stack loading aid is100aused in the order fulfillment facility1a;1b;1c;1d, and/ortransporting the second stack loading aid100bfrom the load securing station to the unloading station and providing the second stack loading aid(s)100beither at an automatically operated unloading device32;65;75;132or on a buffer surface136close to the reloading device32;65;75;132, if a second stack loading aid100bis used in the order fulfillment facility1a;1b;1c;1d, and/ortransporting the second stack loading aid100bfrom the load securing station to the unloading station and providing the second stack loading aid(s)100beither at a semi-automated unloading device151or on a buffer surface153bclose to the unloading device151, if a second stack loading aid100bis used in the order fulfillment facility1a;1b;1c;1d.

InFIGS.13ato13dand14aand14b, the transfer device147is provided for automatically unloading a transport loading aid7,107with article carriers3stacked on top of one another and for loading a target loading aid34,134with article carriers3by clamping gripping. This means that no suction gripping is provided, which would strongly limit the range of different article carriers3. The transfer device147comprises a clamping gripper unit, in particular the clamping jaws254a,254b.

Such a transfer device147may be used at an automatically operated unloading device32,65,75,132of the unloading station (reloading station) described above for an order fulfillment facility1a,1b,1c,1d. The unloading device32,65,75,132(reloading device) comprises the transfer device147, which is spatially movable relative to a support construction42,142. The transfer device147is movable in an x-y-z direction and rotatable around a vertical axis (z-axis).

The transfer device147comprises:a base frame250,loading tongues252a,252bmovable by first drive devices251a,251brelative to the base frame250and in a first direction (y) independently of one another between a retracted initial position (as shown inFIGS.13a,13bwith full lines) and an extended receiving position (as shown inFIGS.14a,14bwith dashed lines), said loading tongues receiving at least one article carrier3in an extended receiving position,clamping jaws254a,254bmovable relative to one another in a second direction (x) by at least one second drive device253a,253bbetween a retracted opened position (as shown inFIGS.13c,13dwith dashed lines) and an abutting clamping position (as shown inFIGS.13c,13dandFIGS.14a,14bwith full lines), anda lifting frame256movable in a third direction (z) relative to the base frame250using at least one third drive device255, on which lifting frame the clamping jaws254a,254bare mounted and by means of which the clamping jaws254a,254bare movable between a lower height position (as shown inFIG.15c) and an upper height position (as shown inFIG.15d), such that, for unloading the transport loading aid7,107,the at least one article carrier3may be lifted by the clamping jaws254a,254bset against the at least one article carrier3(FIG.15d), andat least one of the loading tongues252a,252bmay be pushed at least partially under the at least one article carrier3lifted by the clamping jaws254a,254bin order to receive the at least one article carrier3in the extended receiving position (FIGS.15eand15f).

In the embodiment shown, the clamping jaws254a,254bare movable using second drive devices253a,253bbetween the retracted opened position and the abutting clamping position. However, only one of the clamping jaws254a,254b, for example the first clamping jaw254a, may be movable relative to the second clamping jaw254busing one single second drive device253a.

As indicated inFIG.13c, the first clamping jaw254aand the second clamping jaw254bform clamping jaw webs running parallel to one another, which, in the abutting clamping position of the clamping jaws254a,254b, are brought into contact with the article carrier walls265a,265bof an article carrier3facing away from one another or the article carrier walls265a(FIG.14a) of article carriers3(FIG.16f) arranged next to one another. The clamping jaw webs may also form spring tongues separated by slots, which may also be placed against uneven article carrier walls265a,265bparticularly well.

The transfer device147may also comprise a stop device with one or multiple stop elements257a,257bagainst which the at least one article carrier3may be placed, especially if the latter is on the loading tongues252a,252b(FIG.14a) which have been moved into the extended receiving position or on the loading tongue252b(FIG.14b) which has been moved into the extended receiving position.

According to a possible embodiment, the first clamping jaw254ais arranged on a first clamping jaw frame258a, and the second clamping jaw254bis arranged on a second clamping jaw frame258b, wherein one of the first and second clamping jaw frames258a,258bis adjustable in a second direction (x) at least between a first configuration width and a second configuration width using at least one fourth drive device259, so as to receive an article carrier3with a first longitudinal dimension (as shown inFIG.14a—for example 600 mm) in the first configuration width between the first clamping jaw254aand the second clamping jaw254band to receive an article carrier3with a second longitudinal dimension (as shown inFIG.14b—for example 300 mm) in the second configuration width between the first clamping jaw254aand the second clamping jaw254b.

By the change in width, the transfer device147may also manipulate article carriers3with different longitudinal dimensions. Although only a first configuration width and a second configuration width are shown, additional configuration widths may also be additionally set as well.

It can also prove advantageous if at least one of the clamping jaws254a,254b, for example the clamping jaw254a, as indicated inFIG.13a, for loading the target loading aid is34,134additionally movable in the first direction (y) relative to the frame250into a retracted release position using a fifth drive device260a,260b. In the retracted release position, the stop element(s)257a,257bproject(s) beyond the mentioned at least one clamping jaw254a,254b, such that, for loading the target loading aid34,134, the at least one article carrier3may be stacked onto the target loading aid34,134unhindered by the at least one loading tongue252a,252b. This is shown inFIGS.15jto15k. This embodiment is advantageous as the clamping of the article carrier3may be maintained until just before the article carrier3is discharged.

Basically, it is also conceivable that the first clamping jaw254aand the second clamping jaw254bare each additionally movable in the first direction (y) relative to the frame250into a retracted release position using a fifth drive device260a,260b.

As can be seen in the figures, the second drive device253a,253band one of multiple stop elements257a,257bof the stop device are also mounted at the first or second clamping jaw frame258a,258b. If the fifth drive device260a,260bis present as well, it is also mounted at the first or second clamping jaw frame258a,258b.

The unloading device32;65;75;132comprises a control device261, as schematically shown inFIG.13a, which is connected to the first drive device251a,251b, the second drive device253a,253b, the third drive device255and, if applicable, the fourth drive device259, and, if applicable, the fifth drive device260a,260b. The first, second, third, and, if applicable, fourth, fifth drive devices251a,251b,253a,253b,255, (259), (260a,260b) comprise electric and/or fluidic linear drives, for example.

The transfer device147may also be equipped with a first sensor mechanism, by means of which the removing operation may be monitored during removal of the at least one article carrier3from the transport loading aid7,107. For example, a stack height of the article carrier stack8is detected. Based on the stack height and by detection of the article carriers3which are to be unloaded at the unloading device32;65;75;132, the exact receiving level at which the loading tongue(s)252a,252bare to be extended into the receiving position may be determined. According to the embodiment shown, the first sensor mechanism comprises, at the first or second clamping jaw frame258a,258b, pivotably mounted sensing fingers262a,262b, which are pivoted outward in their starting position (FIG.13a,13b) and pivoted inward in their actuating position (FIG.14a,14b). The starting position and the actuating position may be detected using an inductive proximity switch (initiator), which is not shown. Preferably, the sensing fingers262a,262bare autonomously pivoted outward into the starting position. In the alternative, however, the first sensor mechanism may also comprise one or multiple contactless sensors, for example optical sensors, which may be used for the same purpose.

On the other hand, the unloading device32;65;75;132may be equipped with the first sensor mechanism, by means of which a stack height of the article carrier stack8may be detected during removing of the at least one article carrier3from the transport loading aid7,107, as is not shown in detail. The first sensor mechanism comprises, for example, an image capturing system having at least one camera and one image evaluation unit.

The transfer device147may also be equipped with a second sensor mechanism, by means of which the loading operation may be monitored during loading of the target loading aid34,134. For example, a stack height of the order stack101and/or proper loading of an article carrier3on the order stack101, as well as the positioning/orientation/inclination of the article carriers3in the order stack101are detected. Moreover, collision monitoring prior to loading of the target loading aid34,134is possible.

The second sensor mechanism may comprise one or multiple contactless sensors, for example optical sensors. On the other hand, the transfer device147and/or the unloading device32;65;75;132may be equipped with the second sensor mechanism, which may be used for the same purpose. The second sensor mechanism comprises, for example, an image capturing system having at least one camera and one image evaluation unit.

However, the control device261may also be connected to the first sensor mechanism and the second sensor mechanism.

In jointly describedFIGS.15ato15g, a method or a sequence for unloading a transport loading aid, for example a transport loading aid107with article carriers3stacked on top of one another in an accommodating shaft, by clamping gripping. The article carriers3have a first longitudinal dimension, for example 600 mm. One width is 400 mm, for example. The unloading device32;65;75;132is not shown in these figures for the sake of clarity.

FIG.15a(step i) shows the movement of the transfer device147relative to the transport loading aid107by the control device261controlling the spatially movable transfer device147. It can be seen that the sensing fingers262a,262bare still positioned above the uppermost article carrier3.

FIG.15b(step ii) shows the positioning of the transfer device147relative to the article carrier stack8, in particular with the aid of the first sensor mechanism. If the first sensor mechanism comprises the sensing fingers262a,262b, the sensing fingers262a,262bare actuated by a lowering motion of the transfer device147, such that they are moved into the actuating position. As already described above, the positioning of the transfer device147relative to the article carrier stack8may also be performed by an optical sensor or an image processing system (first sensor mechanism).

As shown inFIG.15c(step iii), the transfer device147has reached the desired relative position (height position (z), width position (x) and depth position (y)) in which the clamping jaws254a,254bare positioned laterally beside article carrier walls265a,265b(see alsoFIG.14a) of an article carrier3. The clamping jaws254a,254bare in the retracted opened position. The transfer device147remains in the relative position until the steps according toFIGS.15dto15f(steps iv to vii) have been performed.

FIG.15d(step iv) shows the clamping of the article carrier3by actuating the at least one second drive device253a,253bfor moving the clamping jaws254a,254bin the second direction (x) relative to one another and from a retracted opened position into the abutting clamping position, and lifting of the article carrier3of at least one stack layer by the clamping jaws254a,254bplaced against the article carrier3by actuating the at least one third drive device255for moving the lifting frame256in the third direction (z) relative to the base frame250and moving the clamping jaws254a,254bout of the lower height position into the upper height position.

FIG.15e(step v) shows the sliding of both loading tongues252a,252bunder the lifted article carrier3by actuating the first drive devices251a,251brelative to the base frame250to receive the article carrier3in the extended receiving position.

FIG.15f(step vi) andFIG.14ashow the receiving position of the loading tongues252a,252b, in which the loading tongues252a,252bare completely extracted and the article carrier3loads the loading tongues252a,252b. It may be advantageous in an optional step vii) if the clamping of the article carrier3is released for a short period of time by actuating the at least one drive device253a,253bby moving at least one of the clamping jaws254a,254bin the second direction (x) from the abutting clamping position into the retracted opened position, such that the article carrier3tilts onto the loading tongues252a,252b.

If optional step vii) is performed, the article carrier3is subsequently clamped again by actuating the at least one drive device253a,253bby moving the clamping jaws254a,254bin the second direction (x) relative to one another and from a retracted opened position into the abutted clamping position.

FIG.15ashows the movement of the transfer device147relative to the transport loading aid107by the control device261controlling the spatially movable transfer device147.

The control device261is configured for controlling the transfer device147and the first/second/third drive device(s)251a,251b,253a,253b,255for unloading an article carrier3so as to carry out the method steps i) to vii).

In jointly describedFIGS.15hto15n, a method or a sequence for loading a target loading aid, for example a target loading aid34in a stack loading aid100a, is shown. For the sake of clarity, only sections of the stack loading aid100aare shown.

After step vi) or, if applicable, step vii), the transfer device147with the article carrier3held between the clamping jaws254a,254bis moved relative to the target loading aid34by the control device261controlling the spatially movable transfer device147, as shown inFIG.15h(step i).

FIG.15hshows that the target loading aid34has already been loaded with some article carriers3. The additional article carrier3is to be placed on the article carrier3′, which is shown hatched and is already at the target loading aid34. The article carrier3′ is in the edge region of the stack wall206b.

FIG.15i(step ii) shows the positioning of the transfer device147(with the additional article carrier3) relative to the order stack101, in particular with the aid of the second sensor mechanism. InFIG.15i, the transfer device147and/or the article carrier3in are in an intermediate position (height position (z), width position (x) and/or depth position (y)).

FIG.15j(step iii) shows how for loading the target loading aid34, the clamping jaw254b, which faces the stack wall206b, is moved in the first direction (y) relative to the frame250and into the retracted release position using the fifth drive device260b. As can be seen, the stop element(s)257a,257bproject(s) beyond the mentioned clamping jaw254bafter the latter has been moved into the release position.

FIG.15k(step iv) shows the positioning of the transfer device147and/or of the article carrier3from the intermediate position (height position (z), width position (x) and/or depth position (y)) into the end position (height position (z), width position (x) and depth position (y)), in which the additional article carrier3may be loaded onto the article carrier3′ already located at the target loading aid34. The article carrier3may be positioned into the end position by moving the transfer device147.

FIG.15l(step v) shows the movement of the clamping jaw254afrom the abutting clamping position into the retracted opened position. The article carrier3still stands on the loading tongues252a,252bif both loading tongues252a,252bhave been moved into the receiving position, or on one of the loading tongues252a,252bif only one of the loading tongues252a,252bhas been moved into the receiving position.

FIG.15m(step vi) shows loading/discharge of the article carrier3onto the article carrier3′. For this purpose, the loading tongues252a,252bare moved into the retracted initial position if both loading tongues252a,252bhave been moved into the receiving position, or the one loading tongue252a,252bis moved into the retracted initial position if only one of the loading tongues252a,252bhas been moved into the receiving position.

FIG.15nshows the movement of the transfer device147relative to the transport loading aid107by the control device261controlling the spatially movable transfer device147.

It should be noted at this point that, from the transfer device147, either an individual article carrier3or a partial article carrier stack may be removed from the transport loading aid7,107and loaded onto the target loading aid34,134. Instead of an article carrier3having the first longitudinal dimension (for example 600 mm), two article carriers3having the second longitudinal dimension (for example 300 mm) may simultaneously be removed from the transport loading aid7,107and loaded onto the target loading aid34,134. The width dimensions are preferably identical, for example 400 mm.

It is also possible that for stabilizing the order stack101, one or multiple empty article carriers3are stacked between stack layers in a stack plane. If the article carriers are collapsible containers, a collapsed container or multiple collapsed containers are stacked in a stack plane between stack layers. This is also performed automatically by the transfer device147.

In jointly describedFIGS.16ato16n, a method or a sequence for unloading a transport loading aid, for example a transport loading aid107with article carriers3,3′ stacked on top of one another in an accommodating shaft and arranged next to one another in a stack layer, by clamping gripping. The article carriers3,3′ have a second longitudinal dimension, for example 300 mm. One width is 400 mm, for example. The unloading device32;65;75;132is not shown in these figures for the sake of clarity.

FIG.16a(step i) shows the movement of the transfer device147relative to the transport loading aid107by the control device261controlling the spatially movable transfer device147. It can be seen that the sensing fingers262a,262bare still positioned above the uppermost article carriers3,3′.

FIG.16b(step ii) shows the positioning of the transfer device147relative to the article carrier stacks8,8′, in particular with the aid of the second sensor mechanism. If the first sensor mechanism comprises the sensing fingers262a,262b, the sensing fingers262a,262bare actuated by a lowering motion of the transfer device147, such that they are moved into the actuating position. As already described above, the positioning of the transfer device147relative to the article carrier stacks8,8′ may also be performed by one or multiple optical sensor(s) or an image processing system (first sensor mechanism).

As shown inFIGS.16cand16d(step iii), the transfer device147has reached the desired relative position (height position (z), width position (x) and depth position (y)) in which the clamping jaws254a,254bare positioned laterally beside article carrier walls265afacing away from one another of article carriers3,3′ arranged next to one another. The clamping jaws254a,254bare in the retracted opened position. The transfer device147remains in the relative position until the steps according toFIGS.16dto16n(steps iv to ix) have been performed.

FIGS.16eand16f(step iv) show the clamping of the article carriers3,3′ arranged next to one another by actuating the at least one second drive device253a,253bfor moving the clamping jaws254a,254bin the second direction (x) relative to one another and from a retracted opened position into the abutting clamping position, and simultaneously lifting the article carriers3,3′ arranged next to one another of at least one stack layer by the clamping jaws254a,254bplaced against the article carriers3,3′ by actuating the at least one third drive device255for moving the lifting frame256in the third direction (z) relative to the base frame250and moving the clamping jaws254a,254bout of the lower height position into the upper height position.

FIGS.16gand16h(step v) show sliding one of the loading tongues252a,252b, namely specifically of loading tongue252b, under one of the article carriers3lifted and arranged next to one another by actuating one of the first drive devices251a,251b, namely specifically the first drive device251b, relative to the base frame250to receive the one of the article carriers3in the extended receiving position.

FIGS.16iand16j(step vi) show the receiving position of the loading tongue252b, in which the loading tongue252bis completely extracted and the article carrier3loads the loading tongue252b.

FIGS.16kand16l(step vii) show the short releasing of the clamping of the article carriers3,3′ by actuating the at least one second drive device253a,253bin order to move at least one of the clamping jaws254a,254bin the second direction (x) from the abutting clamping position into the retracted opened position, such that the article carrier3′, which is not supported from below, tilts back onto the article stack8′ in the transport loading aid107.

FIG.16m(step viii) shows the change of the configuration width from the first configuration width (seeFIGS.16k,16l) to the second configuration width (FIG.16m) using the at least one fourth drive device259in a second direction (x).

FIG.16n(step ix) shows the clamping of the article carrier3, which is received on the loading tongue252amoved into the extended receiving position, by actuating the at least one second drive device253a,253bfor moving the clamping jaws254a,254brelative to one another in the second direction (x) and from a retracted opened position into the abutting clamping position.

FIG.16oshows the movement of the transfer device147relative to the transport loading aid107by the control device261controlling the spatially movable transfer device147.

The control device261is configured for controlling the transfer device147and the first/second/third drive device(s)251a,251b,253a,253b,255,259for unloading an article carrier3so as to carry out the method steps i) to ix).

If after loading the target loading aid34,134with the article carrier3, the article carrier3′ is supposed to be loaded onto the target loading aid34,134as well, for unloading according to method steps i) to vii), the approach according toFIGS.15ato15fis performed, with the mere difference that the second configuration width remains adjusted or is adjusted, in which the article carrier3′ with the second longitudinal dimension is received between the first clamping jaw254aand the second clamping jaw254b.

As regards the loading of a target loading aid, reference is made to the disclosure regardingFIGS.15hto15m, and it is performed in the same manner, with the mere difference that the article carrier3is unloaded using one of the loading tongues252a,252b.

It should be noted at this point that, using the transfer device147, either an individual article carrier3,3′ or a partial article carrier stack may be removed from the transport loading aid7,107and loaded onto the target loading aid34,134.

The described order fulfillment facility and method for storing and picking is particularly suitable for the fresh food sector where perishable goods, such as fresh fruit and vegetables, require a fast turnover of articles and usually only a limited number of different types have to be picked at the same time. The articles2/article carrier3may be handled particularly efficiently with a high picking performance in short periods of time.

Finally, it should also be noted that the scope of protection is determined by the claims. However, the description and the drawings are to be adduced for construing the claims. Individual features or feature combinations from the different exemplary embodiments shown and described may represent independent inventive solutions.

In particular, it should also be noted that the devices shown may in reality comprise more or fewer components than those shown. In some cases, the shown devices and/or their components may not be depicted to scale and/or be enlarged and/or reduced in size.

LIST OF REFERENCE NUMBERS

1a. . .1dorder fulfillment facility2article(s)3article carrier4delivery zone5storage area6order processing zone7,7a. . .7ftransport loading aid8article carrier stack8′ (pre-) picked article carrier stack8″ (pre-) picked article carrier partial stack9transport vehicle (floor conveyor)10article carrier stack group11depalletizing device12a,12bconveying device13loading device14a,14bconveying device15a,15btransfer location16a,16bprovisioning location17transfer device loading device18support construction19gantry slide20gantry arm30buffer surface loading station31storage surface32unloading device33conveying device34a. . .34ctarget loading aid35conveying device36buffer surface unloading station/reloading station37waiting zone40a. . .40bprovisioning location41transfer device unloading device/reloading device42support construction43gantry slide44gantry slide45gantry arm46order-processing computer47control system50chassis51loading platform52wheel53steerable wheel54drive control55base56afirst side wall56b,56dfirst side wall56csecond side wall57loading and unloading opening57a,57bloading and unloading opening58placing surface59transport surface60adjustable foot61lead-in chamfer65unloading device66buffer surface66a,66bbuffer surface67a,67bprovisioning location68a,68bconveying device69transfer device70a,70btake-over location71a,71bprovisioning location75unloading device76buffer surface76a,76bbuffer surface77a,77bprovisioning location81support construction82gantry slide83overhead arm84transfer device90cleaning robot91a,91btemperature zone92a,92bdata carrier92cdata carrier100a,100bstack loading aid101order stack107transport loading aid112a,112bconveying device113loading device114a,114bconveying device117transfer device118support construction119gantry slide120gantry arm132unloading device134target loading aid136buffer surface stack loading aid139a. . .139bprovisioning location stack loading aid automatic unloading device142support construction143gantry slide144gantry arm145gantry slide146gantry slide147transfer device unloading device/reloading device150transport loading aid151unloading device152aprovisioning location transport loading aid automatic unloading device152bprovisioning location stack loading aid automatic unloading device153abuffer surface transport loading aid153bbuffer surface stack loading aid154a,154blifting platform155working area156working surface160loading device161provisioning location second loading device162transfer device163buffer surface170lading device171provisioning location lading device172transfer device173buffer surface180load securing device181securing means182provisioning location183lifting frame184telescopic fork185buffer surface200a,200bside wall part201a,201bbase wall part205base206a,206bstack wall207placing surface208transport surface210receiving channel211placing block212adjustable foot250base frame251a,251bfirst drive device loading tongue252a,252bloading tongue253a,253bsecond drive device clamping jaw254a,254bclamping jaw255third drive device lifting frame256lifting frame257a,257bstop element258a,258bclamping jaw frame259fourth drive device adjustment width configuration260a,260bfifth drive device clamping jaw release position261control device262a,262bsensing finger265a,265barticle carrier wall