Bin Retrieval Track for Automated Warehouse Sortation

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Solution Overview

Problem

Existing automated material handling systems in warehouse and distribution environments are labor-intensive and costly, with limitations in efficiently sorting and retrieving items, particularly in large storage areas, and lack effective methods for automatically transferring full bins to separate locations.

Innovation Solution

A system comprising a storage assembly with bins and a controller that identifies full bins, a retrieval system to automatically retrieve and transfer bins from storage locations, and a mechanism to shake bins to settle contents, ensuring efficient sorting and retrieval processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated picking systems are implemented to reduce labor cost and improve customer service, then productivity and service speed are improved, but device complexity and system cost increase significantly

Engineering Contradiction:

Improveorder fulfillment speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the automated picking function into separate modules: a sortation system that sorts items into bins, and a retrieval system that independently retrieves bins. This segmentation allows each module to be optimized separately and reduces overall system complexity while maintaining high productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retrieval system is designed to perform multiple functions: it retrieves full bins from the sortation system, transfers them to storage locations, and can also retrieve bins from storage locations. This multi-functionality reduces the need for separate specialized systems, thereby reducing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If manual sorting and retrieving is performed in large storage areas, then device complexity is low, but productivity and time to fill customer orders are significantly reduced

Engineering Contradiction:

Improveitem sorting and retrieval speedVSAvoidautomation system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The sortation system automatically identifies items and directs them to appropriate bins without human intervention. The retrieval system automatically monitors bin fullness and retrieves bins when full, enabling the system to serve itself and eliminating the need for continuous manual monitoring and operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The controller continuously monitors the sortation and retrieval processes, tracking item flow and bin status. This feedback mechanism allows the system to automatically adjust operations, optimize performance, and maintain high productivity without complex manual control systems.

Inventive Principle:

Principle #23Feedback

3Productivity

If bins are not shaken to settle contents, then device complexity is low, but storage capacity and efficiency are reduced

Engineering Contradiction:

Improvestorage capacity utilizationVSAvoidbin handling mechanism complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The retrieval system periodically shakes bins at predetermined intervals or when sensors detect unsettled contents. This periodic action is sufficient to settle items and maximize storage capacity without requiring continuous or complex settling mechanisms.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The retrieval system incorporates a shaking mechanism that applies mechanical vibration to bins during retrieval or at storage locations. This vibration settles loose items in the bins, optimizing storage capacity and preventing item displacement during subsequent handling.

Inventive Principle:

Principle #18Mechanical vibration

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 system significantly reduces labor costs and improves efficiency by automating the retrieval and transfer of full bins, enabling seamless sorting and processing of items, while also addressing the need for settling contents in bins to optimize storage capacity.

Implementation Method 1

transfer means configured to transfer the bin onto the retrieval system from the storage location

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS12172833B2Material handling system with automatic retrieval of sorted items

Publication Date: 2024.12.24 OPEX CORP

AI summary

A system may include a vehicle for delivering items and a moveable track that cooperates with the vehicle. The moveable track may cooperate with a storage system having storage locations for storing items. The vehicle may drive into the moveable track and lift the track using a vertical drive mechanism. The vehicle may include a horizontal drive system operable to drive the vehicle horizontally along the ground to carry the moveable track to a position adjacent the storage location. The vehicle may operate the vertical drive system to drop the moveable track adjacent the storage system. Additionally, the vehicle may operate the vertical drive to drive up the moveable track to an elevated position adjacent one of the storage locations in the storage system. The vehicle may include a transfer mechanism for transferring items between the vehicle and the storage location while the vehicle is in the elevated position.