Integrated Container Handling for High-Volume Order Processing
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Solution Overview
Problem
Existing order processing systems face inefficiencies in handling and sorting large volumes of containers, particularly in systems that handle tens of thousands of bin retrievals per hour and numerous customer orders with multiple items, requiring extensive conveyor systems and significant resources.
Innovation Solution
The system integrates a storage-and-retrieval system with robotic load handlers and a unified framework for managing both storage and delivery containers, allowing for efficient storage, retrieval, and handling of containers within a single system, reducing the need for separate order container handling and sortation systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate order sortation and handling systems are used, then container handling can be performed, but floor space requirements increase and system complexity increases
Solution Approach 1:
The patent combines the storage and retrieval system with the order sortation and handling system into a single integrated system. The storage and retrieval system directly provides container sortation and handling capabilities, eliminating the need for separate order sortation systems. This merging reduces floor space requirements while maintaining full container handling functionality.
2Ease of operation
If separate order sortation and handling systems are used, then container handling can be performed, but device complexity increases
Solution Approach 1:
The patent merges multiple separate systems (storage and retrieval, order sortation, and container handling) into a single integrated system. This consolidation reduces the number of separate devices and interfaces, thereby reducing overall system complexity while maintaining comprehensive container handling capabilities.
Solution Approach 2:
The storage and retrieval system is designed to perform multiple functions: storing containers, retrieving containers, and providing order sortation and handling capabilities. This multi-functionality eliminates the need for specialized separate systems, reducing device complexity.
3Productivity
If extensive conveyor systems are used, then large volumes of containers can be handled, but investment costs increase and operating costs increase
Solution Approach 1:
The robotic load handlers autonomously perform container retrieval, transport, and sortation tasks without requiring extensive conveyor infrastructure. The system uses the storage and retrieval framework itself for container movement and positioning, eliminating the need for separate extensive conveyor systems while maintaining high handling volumes.
4Productivity
If extensive conveyor systems are used, then large volumes of containers can be handled, but loss of energy increases
Solution Approach 1:
The patent replaces extensive mechanical conveyor systems with robotic load handlers that use more efficient movement mechanisms. The robotic handlers directly transport containers between storage locations and sortation points, eliminating the energy-intensive continuous operation of extensive conveyor systems while maintaining high handling volumes.
Data Source
AI summary
Systems, methods, and machine-executable coded instruction sets are disclosed for fully- and/or partly automated handling of goods. The disclosure provides improvements in the storage and retrieval of storage and delivery containers in order processing systems.