Robotic Consolidation for Storage Density
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Solution Overview
Problem
Stowing robots face challenges in maximizing storage density due to the use of stow buffers, which are necessary to account for inaccuracies in item placement, leading to gaps between items of different sizes and shapes, reducing the effective use of container space.
Innovation Solution
A consolidation robot that reduces stow buffers by tilting and vibrating the tray, allowing items to move closer together, thereby increasing storage density without risking overlap, using a combination of mechanical and vibrational actions to optimize item placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stow buffers are used to account for placement inaccuracies, then item placement reliability is improved, but storage density deteriorates due to gaps between items
Solution Approach 1:
The system applies mechanical vibration to items on the tray to cause them to shift and settle into tighter configurations. The vibration mechanism causes items to oscillate and gradually move closer together, reducing the stow buffers between adjacent items while maintaining proper placement through controlled vibration parameters.
Solution Approach 2:
The system changes physical parameters of the tray system by tilting the tray to different angles and applying vibrations at specific frequencies and amplitudes. These parameter changes enable items to transition from a loose placement state to a densely packed state, optimizing storage density while preventing overlap through controlled parameter adjustment.
2Quantity of substance
If items are placed tightly together to maximize storage density, then storage capacity is improved, but the risk of item overlap increases due to placement inaccuracies
Solution Approach 1:
The vibration mechanism allows items to self-adjust their positions after initial placement. By applying vibration, items that were initially placed with stow buffers can shift and settle into optimal positions, achieving tight packing without requiring extremely precise initial placement, thus reducing the impact of placement inaccuracies.
Solution Approach 2:
The system transitions from a static placement approach to a dynamic consolidation process. Items are first placed with generous buffers, then the tray is tilted and vibrated to dynamically adjust item positions. This dynamic approach allows the system to compensate for initial placement imprecision while achieving high storage density.
3Manufacturing precision
If stow buffers are increased to prevent item overlap, then placement accuracy is improved, but unused space increases reducing storage efficiency
Solution Approach 1:
The vibration mechanism eliminates the need for large stow buffers by allowing items to settle into tight configurations after placement. Items that are initially placed with buffers can be vibrated to move closer together, converting the unused buffer space into additional storage capacity while maintaining placement accuracy through the consolidation process.
Solution Approach 2:
The system extracts the function of preventing item overlap from the initial placement phase and transfers it to the consolidation phase. Instead of relying on large buffers during placement, the system uses vibration and tilting to actively prevent overlap during the consolidation process, thereby eliminating the need for excessive stow buffers and improving storage efficiency.
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
This approach increases the number of items that can be stored in a container by reducing unused space, enhancing storage efficiency while ensuring items can still be retrieved accurately without overlap, thus improving overall storage capacity.
Implementation Method 1
A consolidation robot that reduces stow buffers by tilting and vibrating the tray, allowing items to move closer together
Implementation Method 2
A consolidation robot that reduces stow buffers by tilting and vibrating the tray, allowing items to move closer together
Data Source
AI summary
Embodiments herein describe a robotic pick and stow storage system with a built-in consolidation function that increases the storage density. The system can include a stowing robot, a consolidation robot, and individual containers. The stowing robot may pick an item, identify a free space in the container large enough for the item, and then place the item in the free space. The items placed in the container may have a space between it and a neighboring item or items (referred to herein as a stow buffer) due to uncertainties or inaccuracies in the stowing process. The embodiments herein describe a stow and consolidation action that reduces the stow buffers thereby providing additional space in the container for more items. The consolidation robot can tilt and vibrate the container such that the items move closer together thereby generating free space for additional items in the container.