Multi-Level Carrier Retrieval for Faster Warehouse Item Staging
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Solution Overview
Problem
The existing delivery and packaging processes in warehouse facilities are time-intensive and inefficient, with packaging materials often discarded after use, and traditional delivery methods are slow and involve frequent handling and separate shipping of items to customers in similar areas, utilizing vehicles with limited capacity.
Innovation Solution
An item retrieval system comprising a moveable trailer with a support structure and carriers that move along pathways to index and sort containers, utilizing an advancement mechanism with a rotating disk and extendable arm to position containers for unloading by a robotic manipulator, allowing for efficient sorting and delivery of items directly to customers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional delivery methods are used, then items can be delivered to customers, but the delivery process is long and slow and items are moved and handled frequently
Solution Approach 1:
The system performs preliminary sorting and staging of items in a portable facility before final delivery. Carriers are pre-positioned with items on multiple levels, and the robotic manipulator prepares items for transfer in advance, reducing the need for frequent handling during transit and accelerating the overall delivery process.
Solution Approach 2:
The portable facility is divided into multiple levels with carriers arranged vertically. The robotic manipulator operates independently to transfer items between levels and to delivery vehicles, segmenting the delivery process into efficient discrete operations that reduce handling time and increase speed.
2Productivity
If items are sorted and packaged in a warehouse facility, then items can be prepared for delivery, but the process is time intensive and packaging material is discarded
Solution Approach 1:
The robotic manipulator autonomously performs sorting and transfer operations without human intervention. The system self-manages the sorting process by automatically retrieving items from carriers, transferring them to delivery vehicles, and returning empty carriers to storage positions, significantly reducing sorting time and eliminating the need for discarded packaging materials.
Solution Approach 2:
The patent replaces traditional manual sorting and packaging operations with an automated robotic system. The robotic manipulator uses mechanical arms and grippers to handle items, replacing human labor and traditional packaging processes, thereby increasing productivity while eliminating time-intensive manual sorting and reducing packaging waste.
3Adaptability or versatility
If items to customers in similar areas are shipped separately, then each customer receives their order, but vehicle capacity is not optimized and delivery efficiency decreases
Solution Approach 1:
The portable facility is designed to accommodate multiple types of carriers and items on its multi-level structure. The robotic manipulator can handle various item types and transfer them to different delivery vehicles, allowing the system to consolidate shipments for multiple customers in similar areas into a single optimized delivery route, improving both versatility and efficiency.
Data Source
AI summary
An item retrieval system can include a support defining a continuous pathway having an upper level, a lower level, and an end portion connecting the upper and lower portions. An advancement mechanism can move a carrier having a container advanced along the continuous pathway between the upper and lower levels.