Adaptive Robotic Retrieval for Dense Container Racks

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Solution Overview

Problem

Robots with limited reach struggle to access containers stored beyond a specified distance, leading to inefficient warehouse layouts with wasted space and reduced container density due to the need to accommodate their reach limitations.

Innovation Solution

A robotic retrieval system that adapts to dense container arrangements by coordinating robot operations to reposition containers, leveraging tracked states and predictive analytics to optimize access and placement, allowing robots to efficiently retrieve containers from any position without extending their reach.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If rack configurations are adapted to hold only one container on either side to accommodate robot reach limitations, then robots can retrieve containers, but container density decreases and warehouse space is wasted

Engineering Contradiction:

Improverobot container retrievalVSAvoidcontainer density

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The system segments the container retrieval task into multiple robotic operations. Instead of requiring single-step direct access, the controller coordinates multiple robots to perform sequential operations: one robot retrieves a blocking container while another simultaneously places a new container in the same slot. This segmentation enables deep stacking without compromising retrieval capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions by predicting future container retrieval needs using access history and priority information. High-priority containers are proactively moved to accessible positions before they are actually requested, ensuring that when retrieval is needed, the container is already in a reachable position without requiring aisle navigation.

Inventive Principle:

Principle #10Preliminary action

2Quantity of substance

If robots are given extended reach to access deeper containers, then container density can increase, but robot hardware complexity and cost increase

Engineering Contradiction:

Improvecontainer densityVSAvoidrobot hardware

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The system merges the capabilities of multiple robots with limited reach to achieve the functional equivalent of a single robot with extended reach. By coordinating multiple units working in parallel on the same rack, the system achieves deep container access without requiring any individual robot to have extended mechanical reach, thereby avoiding the complexity and cost of such modifications.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If aisles are widened to accommodate robot navigation for deep container access, then robots can reach any container, but warehouse space utilization decreases

Engineering Contradiction:

Improvecontainer accessibilityVSAvoidwarehouse space utilization

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The system implements dynamic container positioning where container accessibility is not fixed but changes over time based on operational needs. The controller continuously monitors access patterns and dynamically repositions containers to optimize accessibility, transforming the static warehouse layout into a dynamic system that adapts to retrieval demands without requiring physical aisle modifications.

Inventive Principle:

Principle #15Dynamics

4Quantity of substance

If multiple robots coordinate to reposition containers in densely stacked racks, then container density increases, but the number of robotic operations increases

Engineering Contradiction:

Improvecontainer densityVSAvoidnumber of movements

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The system maintains continuity of useful action by overlapping robotic operations. While one robot is retrieving a container, another robot simultaneously places a new container in the same slot. This parallel execution eliminates idle time between retrieval and restocking operations, ensuring continuous productive activity despite the increased number of movements required for dense stacking.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS12391479B2Systems and methods for adapting robotic retrieval to increasingly dense container arrangements

Publication Date: 2025.08.19 INVIA ROBOTICS INC

AI summary

Provided is a robotic retrieval system that adapts robot operations to different densities with which containers are stored. The system determines a position of a particular container in a slot. The system selects a first side of the slot from which to gain access to the particular container based on the particular container being blocked from the first side by a first number of containers and from an opposite second side by a larger second number of containers. The system uses robots to advance the particular container to the frontmost position at the first side of the particular slot by removing the first number of containers from the first side, and by inserting the first number of containers into the second side, and to transfer the particular container to a target destination after advancing the particular container to the frontmost position at the first side.