Autonomous Goods Bots for Multi-Level Breakpack Storage
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Solution Overview
Problem
Conventional automated storage and retrieval systems are limited by a constrained exchange interface between supply containers and breakpack goods containers, which restricts throughput and efficiency in order fulfillment processes.
Innovation Solution
The implementation of autonomous goods bots that traverse multiple levels of a breakpack station, combined with a modular breakpack module design that allows for independent flow of containers, enhances the efficiency and flexibility of order fulfillment by enabling simultaneous processing across multiple vertical levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional automated storage and retrieval systems use a constrained exchange interface between supply containers and breakpack goods containers, then system simplicity is maintained, but throughput and efficiency are restricted
Solution Approach 1:
The system is divided into multiple independent breakpack modules, each capable of processing containers autonomously. Each module has its own exchange interface and processing area, allowing parallel operations across multiple modules. This segmentation enables the system to handle multiple containers simultaneously, significantly increasing throughput without requiring a single complex centralized interface.
Solution Approach 2:
The system transitions from a single-level constrained exchange interface to a multi-level three-dimensional array of storage racks with breakpack modules distributed across multiple vertical levels. Containers can be transferred between different levels and modules simultaneously, utilizing vertical space and creating multiple parallel pathways for container flow, thereby increasing throughput without proportionally increasing interface complexity.
2Productivity
If breakpack stations are arranged on a single common level, then system simplicity is maintained, but throughput is limited due to sequential processing
Solution Approach 1:
Breakpack modules are distributed across multiple vertical levels of the three-dimensional storage rack array rather than being confined to a single common level. This vertical distribution allows containers to be processed at different heights simultaneously, creating parallel processing pathways. The system uses vertical transport mechanisms to move containers between levels, enabling multiple breakpack operations to occur concurrently without increasing the footprint of individual processing areas.
3Ease of operation
If autonomous goods bots traverse multiple levels of breakpack station, then sequencing and sortation efficiency is improved, but device complexity increases
Solution Approach 1:
Autonomous goods bots are equipped with navigation and decision-making capabilities that allow them to independently traverse multiple levels of the breakpack station, locate required containers, and deliver them to appropriate destinations without continuous human intervention. The bots autonomously sequence and sort containers based on destination requirements, reducing the need for complex centralized control systems and manual sorting operations.
Solution Approach 2:
The system replaces manual container handling and sorting operations with autonomous goods bots that use sensors, navigation systems, and automated manipulation mechanisms. This substitution eliminates the need for complex mechanical conveyors and transfer mechanisms that would otherwise be required to achieve the same level of automated sequencing and sortation across multiple levels.
Data Source
AI summary
An automated storage and retrieval system for filling goods in containers, the system including multilevel container storage, each level with transport area and storage area, storage area including storage shelves configured to hold containers, transport area being arranged to connect storage shelves to each other, transport area including picking aisles and a container transfer deck autonomous guided container transport vehicle, located on each level of the multilevel storage and configured to traverse the container transfer deck and picking aisles and transport containers to one goods operation station, a putwall of more than one levels of goods container stations, wherein the putwall communicates with the one goods operation station to receive goods from one goods operation station in the goods container stations and a controller configured to effect operation of one autonomous guided container transport vehicle between the container storage locations and goods container located at goods container station of putwall.