Aerial-Ground Sortation Layout for Warehouse Throughput Limits
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Solution Overview
Problem
Current warehouse sortation systems are limited by floor space, restricting throughput as they operate in a 2D environment, making it inefficient to increase sorting capacity with additional ground-based conveyors or autonomous vehicles.
Innovation Solution
Implementing a combined aerial and ground sortation system where drones operate in 3D space above the floor, working in conjunction with ground-based systems to sort packages into shared containers, using a leading sorter to determine whether packages should be sorted by aerial or ground systems based on weight, size, and other characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ground-based sortation systems are used, then packages can be sorted using existing warehouse infrastructure, but throughput is limited by floor space and 2D operation constraints
Solution Approach 1:
The patent introduces aerial sortation using drones that operate in three-dimensional space above the warehouse floor. This adds a vertical dimension to the traditionally two-dimensional ground-based sortation system, allowing packages to be transported and sorted in the air space above existing containers and shelving, thereby dramatically increasing throughput without requiring additional floor space.
2Productivity
If additional ground-based conveyors or autonomous vehicles are added to increase sorting capacity, then more packages can be handled, but navigation through narrow aisles and chock points creates traffic congestion that limits effectiveness
Solution Approach 1:
Aerial drones bypass the complex two-dimensional navigation challenges of ground-based systems by operating in three-dimensional space. The drones can fly over narrow aisles, chock points, and other obstacles that constrain ground vehicles, eliminating traffic congestion issues while adding sorting capacity.
Solution Approach 2:
The patent introduces aerial drones as an intermediary sortation system that works in parallel with the existing ground-based conveyor and autonomous vehicle systems. The leading sorter determines which packages are routed to aerial drones and which continue through ground-based systems, creating a multi-layered sortation approach that increases capacity without overcomplicating any single system's navigation requirements.
3Productivity
If a combined aerial and ground sortation system is implemented, then throughput increases by utilizing 3D space, but system complexity increases with integration of multiple sortation pathways
Solution Approach 1:
The patent divides the sortation system into distinct segments: a leading sorter that performs initial package classification, aerial drones for specific package types, and ground-based systems for other packages. This segmentation allows each component to operate independently with well-defined interfaces, managing overall system complexity while achieving high throughput through coordinated multi-pathway operation.
Solution Approach 2:
The patent creates a multi-functional sortation system where the leading sorter can route packages to multiple destinations (aerial drones or ground-based systems), and where containers serve dual purposes by being accessible to both aerial and ground sortation pathways. This universality allows the system to handle diverse package types efficiently while maintaining a cohesive integrated architecture.
Data Source
AI summary
Embodiments herein describe a combined aerial and ground sortation system. That is, the system can include both an aerial sortation system and a ground sortation system that work together to sort items (e.g., packages) in a warehouse or building. In one embodiment, the combined aerial and ground sortation system includes a leading sorter that identifies which packages should be sorted using the aerial sortation system and which should be sorted by the ground sortation system. The aerial sortation system may use drones to fly the package to one of the containers and drop the package into the container while the ground sortation system may use drive units that move along a floor of the warehouse to deposit the packages into the container. In another embodiment, the aerial sortation system performs a first, primary sort of the items while the ground sortation system performs a secondary sort.