Container Dispenser Indexing for Automated Tote Loading

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing order-fulfillment systems in retail supply chains face challenges in efficiently transferring containers to totes for customer transport, as customers often require containers that can be easily transported home with their orders.

Innovation Solution

An automated storage and retrieval system integrated with a container dispenser that can transfer one or more containers into a tote, which is then filled with goods and accessed by customers, featuring a dispense module, a table for indexing, and a structure to support the dispenser over the tote.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If containers are manually transferred to totes for customer transport, then customers can easily transport their orders home, but the order fulfillment process is inefficient and labor-intensive

Engineering Contradiction:

Improveorder fulfillment efficiencyVSAvoidcustomer transport convenience

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system automatically performs the container-to-tote transfer operation without manual intervention. The robotic arm picks containers from storage locations and places them into totes based on order requirements, making the system self-serve the need for customer-friendly packaging while maintaining high efficiency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical process of transferring containers is replaced with an automated robotic system. The robotic arm with gripper mechanism substitutes human hands, and the automated control system replaces manual decision-making, achieving both high productivity and proper container placement for customer transport

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If an automated system is introduced to transfer containers to totes, then order fulfillment efficiency improves, but system complexity increases

Engineering Contradiction:

Improveorder fulfillment efficiencyVSAvoidautomation system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The robotic arm system is designed to perform multiple functions: it can pick containers from different storage locations, place them in various positions within totes, and adapt to different container types. This multi-functionality reduces the need for multiple specialized devices, managing complexity while maintaining high productivity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The robotic arm acts as an intermediary between container storage and tote assembly. This single intermediary component handles all transfer operations, simplifying the overall system architecture compared to having separate mechanisms for each transfer operation, thus improving productivity without proportionally increasing complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12570473B2Container to tote dispense integrated with automated storage and retrieval system

Publication Date: 2026.03.10 SYMBOTIC LLC

AI summary

An automated storage and retrieval facility includes a container dispenser which transfers one or more containers into a tote. Once loaded into a tote, the one or more containers may receive goods to fulfill an order. Once filled with goods, the containers may be accessed by customers for transport away from the facility. The container dispenser may include a table configured to move over an opening of a tote to dispense more than one container at different positions within the tote. The container dispenser may be integrated within a storage area of the automated storage and retrieval facility. Alternatively, the container dispenser may be part of workstation positioned away from the storage area.