Bin-Module Retrieval Layout for Fast ASRS Order Picking
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Solution Overview
Problem
Existing automated storage and retrieval systems (ASRS) in limited inventory workspaces are inefficient in quickly retrieving items for order fulfillment, especially when workspace area is constrained.
Innovation Solution
A system comprising multiple storage shelves, dollies that move between shelves, and elevators, with a control system that coordinates the movement of bin modules between shelves and workstations, allowing for efficient retrieval and processing of items by collecting them on a bin module basis rather than individually.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If items are retrieved individually from storage shelves, then retrieval accuracy is improved, but retrieval speed and productivity deteriorate in limited workspace
Solution Approach 1:
The patent combines multiple individual item retrieval operations into a single bin module retrieval operation. The dolly retrieves entire bin modules containing multiple items in one operation, then the system presents all items from that bin module to the workstation simultaneously, merging multiple retrieval actions into one efficient operation that maintains accuracy while boosting productivity
Solution Approach 2:
The system performs preliminary grouping of items into bin modules before retrieval. Items are pre-organized in bin modules based on order requirements, so when a retrieval operation occurs, the correct items are already grouped together and ready for presentation to the workstation, eliminating the need for multiple sequential retrieval operations
2Quantity of substance
If more storage shelves are added to increase inventory capacity, then storage capacity is improved, but workspace area utilization deteriorates in constrained environments
Solution Approach 1:
The patent transitions from horizontal expansion (adding more shelves across the workspace) to vertical expansion (stacking bin modules vertically on existing shelves). The dolly system enables retrieval from elevated positions, allowing the system to utilize vertical space for additional storage capacity without consuming more floor area, effectively moving the storage solution into the third dimension
Solution Approach 2:
The system implements nested storage by placing multiple bin modules vertically within the same shelf footprint. Bin modules are stacked one above another on each shelf location, creating a nested arrangement that maximizes the use of vertical space while maintaining the same horizontal workspace area, effectively nesting storage capacity within the existing structural footprint
3Device complexity
If bin modules are made larger to reduce the number of modules, then device complexity is reduced, but ease of operation deteriorates due to dolly capacity constraints
Solution Approach 1:
The system uses bin modules that are sized to fully utilize the dolly's carrying capacity, even if this means some bin modules contain more items than strictly necessary for a single order. This partial over-capacity approach ensures that each dolly trip retrieves the maximum possible inventory value, reducing the total number of modules and trips needed while the dolly's capacity constraints naturally regulate the optimal bin module size
Data Source
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AI summary
A bin-module based automated storage and retrieval system (ASRS) includes a plurality of storage shelves, each removably supporting a plurality of bin modules. Each bin module includes multiple bins. The system also includes a collection shelf configured to removably support bin modules. The system further includes a dolly including: (a) a dolly frame, (b) a drive module configured to propel the dolly, and (c) an actuator configured to move a coupler to couple to the bin module supported in one of the plurality of storage shelves when the dolly is positioned adjacent to said storage shelf, the actuator being further configured to remove said bin module from said storage shelf to the dolly frame, and to move said bin module from the dolly frame to the collection shelf when the dolly is positioned adjacent to the collection shelf.