Automated Decant System with Robotic Depalletizing and Gravity Drop
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Solution Overview
Problem
Conventional retail inventory replenishment methods are inefficient, relying on manual processes for decanting and organizing products from cases to storage containers, which can lead to increased costs and reduced productivity.
Innovation Solution
An automated decant system that includes a load-staging table with a movable support surface and dividers, a robotic case de-palletizer module, and mobile robots to efficiently transfer products from cases to totes, utilizing conveyor belts and actuators to organize and transfer products with minimal manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes are used for decanting and organizing products, then device complexity is reduced, but productivity and efficiency deteriorate
Solution Approach 1:
The system segments the decanting process into distinct functional modules: a robotic arm for product removal, a conveyor system for transport, dividers for organization, and totes for storage. Each module performs a specific function, allowing the complex overall process to be broken down into manageable, automated tasks that improve productivity while maintaining clear system architecture.
Solution Approach 2:
The conveyor system acts as an intermediary between the robotic arm and the totes, facilitating the transfer of products. This intermediary component enables smooth coordination between different system elements, allowing the robotic arm to focus on product removal while the conveyor handles transport and positioning, thereby improving overall efficiency without requiring direct complex integration between all components.
2Productivity
If manual labor is used for organizing products, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The system employs self-service mechanisms where the robotic arm automatically removes products from cases, the conveyor system autonomously transports them, and the dividers automatically organize products into totes without human intervention. This automation eliminates manual labor while the modular design keeps the system complexity manageable through standardized components and clear functional separation.
3Productivity
If automated robotic systems are used, then productivity increases, but device complexity increases
Solution Approach 1:
The system merges multiple functions into integrated components: the robotic arm combines product removal and placement capabilities, the conveyor system integrates transport and positioning functions, and the dividers combine organization and guidance roles. This merging approach improves productivity through automation while reducing overall system complexity by eliminating the need for separate, uncoordinated systems.
Solution Approach 2:
The robotic arm is designed with multi-functionality, capable of performing both product removal from cases and placement into totes. The conveyor system serves multiple purposes including transport, positioning, and coordination between robotic operations. This universality improves productivity through versatile automation while reducing the total number of components needed, thereby managing system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system significantly reduces manual labor, increases efficiency, and enhances productivity by automating the decanting and organization of products from cases to totes, improving the overall supply chain management in retail environments.
Implementation Method 1
the actuator is configured to withdraw the movable support when the tote is positioned beneath the load-staging table to drop the one or more sets of eaches into the tote
Data Source
AI summary
An automated decant system is disclosed for processing pallets of cased goods received at a facility, extracting packaging for the cases and transferring eaches within the cases to totes, possibly organized by SKU in sub-totes within the tote.