Autonomous Transport Vehicle Sortation for Mixed Pallet Loads
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Solution Overview
Problem
Existing storage and retrieval systems struggle to efficiently sort and assemble case units of varying sizes and SKUs into mixed pallet loads, leading to reduced throughput and inefficiencies in warehouse operations.
Innovation Solution
The system employs autonomous transport vehicles (bots) and lift modules to dynamically sort and assemble case units on the fly, forming structured mixed pallet loads with on-the-fly sortation along multiple axes, allowing simultaneous transport and sorting without dedicated sorters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If case units are sorted and assembled on dedicated sorters before palletizing, then sorting accuracy is improved, but system complexity and throughput time increase
Solution Approach 1:
The patent combines the transport function and sorting function into a single integrated system. The autonomous transport vehicles (bots) perform both transportation and sorting operations simultaneously, eliminating the need for separate dedicated sorters. This merging of functions reduces system complexity while maintaining sorting accuracy through real-time control algorithms that manage vehicle routing and case unit placement.
Solution Approach 2:
The autonomous transport vehicles are designed with multi-functionality, serving both as transport carriers and sorting mechanisms. These bots can dynamically adjust their paths and perform sorting operations at multiple locations within the warehouse, making the system more versatile and reducing the need for specialized equipment for each function.
2Productivity
If case units are sorted during transport using autonomous vehicles, then throughput is improved, but control complexity increases
Solution Approach 1:
The system implements real-time feedback mechanisms where sensors on the autonomous vehicles continuously monitor case unit positions, vehicle locations, and pallet assembly status. This feedback is processed by control algorithms that dynamically adjust vehicle routes and sorting decisions, enabling high throughput while managing control complexity through adaptive rather than purely predetermined control logic.
Solution Approach 2:
The sorting process is made dynamic through the autonomous vehicles that can change their paths and sorting actions in real-time based on current system state. Rather than using fixed, predetermined sorting sequences, the system adapts its control strategies dynamically, allowing multiple case units to be sorted during single transport cycles and improving overall throughput.
3Productivity
If multiple case unit sizes and SKUs are assembled into mixed pallet loads, then warehouse efficiency is improved, but sorting time increases
Solution Approach 1:
The system performs preliminary actions by pre-planning pallet assembly sequences and vehicle routes before actual transport begins. The control system calculates optimal sorting sequences and vehicle paths in advance, allowing multiple case units to be sorted during a single transport cycle without increasing overall sorting time. This pre-computation enables efficient handling of mixed SKUs and sizes.
Solution Approach 2:
The autonomous vehicles maintain continuous useful action by performing sorting operations throughout their entire transport cycle rather than separating transport and sorting into distinct phases. As vehicles travel between storage locations and palletizing stations, they continuously sort and place case units on pallets, maximizing productivity without extending total processing time.
Data Source
AI summary
An automated storage and retrieval system including at least one autonomous transport vehicle, a transfer deck that defines a transport surface for the vehicle, at least one reciprocating lift, a first and second pickface interface station connected to the deck and spaced apart from each other, each station forming a pickface transfer interfacing between the vehicle on the deck and the lift at each station so that a pickface is transferred between the lift and the vehicle at each station, wherein the vehicle is configured to pick a first pickface at the first station, traverse the deck and buffer the first pickface, or at least a portion thereof, at the second station so that the second station has multiple pickfaces buffered on a common support in an order sequence of pickfaces according to a predetermined case out order sequence of mixed case pickfaces.