Abstract: A multi-zone automated storage and retrieval system (ASRS) and a method for controlling operation of robotic storage/retrieval vehicles (RSRVs) therein are provided. The multi-zone ASRS includes first and second storage zones isolated by at least one barrier and including first and second groups of storage locations respectively for accommodating storage units therein. The multi-zone ASRS includes one or more portals opening through the barrier(s) between the storage zones, and at least one track layout. The track layout(s) includes first and second track areas occupying the first and second storage zones respectively, and one or more connective track segments interconnecting the first and second track areas through the portal(s). The RSRVs deposit and retrieve the storage units to and from the storage locations and travel on the first and second track areas via the connective track segment(s) to respectively access the first and second groups of storage locations therefrom.

Abstract: A storage and retrieval system employing a gridded three-dimensional storage structure features workstations served by the same robotic vehicle fleet that serves the storage structure, travel-through workstations using the same robotic vehicles to carry storage units through the workstation without hand-off to any other conveyor or handler, internal sortation using orchestrated navigation of the robotic vehicles to workstation intake points, sensors on the robotic vehicles to confirm proper loading and alignment of storage units thereon, lifting mechanisms for raising the robotic vehicles into shafts of the gridded three-dimensional storage structure from a lower track thereof, use of markers and scanners to align the robotic vehicles with the grid shafts, and workstation light curtains for hand safety, pick-counting and container content protrusion detection.

Abstract: A storage system features a fleet of storage/retrieval vehicles and a gridded three-dimensional structure. The structure features a gridded two-dimensional track layout on which the one or more storage/retrieval vehicles are conveyable in two directions, and a plurality of storage columns residing above or below the gridded track layout in spaced distribution throughout the two-dimensional area of the track layout. Upright shafts reside above or below the gridded track layout and provide vehicle access to the storage columns. At least one working station resides outside the two-dimensional area of the track layout, and via one or more extension tracks, is served by the same vehicles that navigate the gridded structure.

Abstract: Orchestrated delivery of retrieved storage units from a three-dimensional gridded storage structure to an entrance or intake point of a working station in a sequenced manner is performed entirely within the footprint of the gridded three-dimensional storage structure by the same fleet of robotic storage/retrieval vehicles operable to retrieve the storage units from storage locations within that gridded structure, thereby enabling omission of large sortation conveyors or other external sortation equipment.

Abstract: Orchestrated delivery of retrieved storage units from a three-dimensional gridded storage structure to an entrance or intake point of a working station in a sequenced manner is performed entirely within the footprint of the gridded three-dimensional storage structure by the same fleet of robotic storage/retrieval vehicles operable to retrieve the storage units from storage locations within that gridded structure, thereby enabling omission of large sortation conveyors or other external sortation equipment.

Abstract: A storage system features a fleet of storage/retrieval vehicles and a gridded three-dimensional structure. The structure features a gridded two-dimensional track layout on which the one or more storage/retrieval vehicles are conveyable in two directions, and a plurality of storage columns residing above or below the gridded track layout in spaced distribution throughout the two-dimensional area of the track layout. Upright shafts reside above or below the gridded track layout and provide vehicle access to the storage columns. At least one working station resides outside the two-dimensional area of the track layout, and via one or more extension tracks, is served by the same vehicles that navigate the gridded structure.