Container Sequencing Conveyor for Robotic Grid Storage Dispatch
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Solution Overview
Problem
Existing robotic storage and picking systems face challenges in efficiently combining disparate containers into coherent groups for customer orders or delivery routes, particularly in enclosed spaces where the height of the load handler restricts stack height and increases costs, and struggle with sequencing containers for transference between storage systems or to/from fulfillment centers.
Innovation Solution
A storage and picking system featuring a grid-like track framework with robotic load handling devices that lift and deposit containers, utilizing a conveyance system to sequence and dispatch containers in a predetermined order independent of retrieval order, allowing for higher density and throughput, and enabling efficient transference and sorting across different storage systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If robotic load handling devices are used to retrieve containers from stacks, then container access and storage density are improved, but the height of the load handler restricts stack height and increases system costs
Solution Approach 1:
The system divides the container handling function into two separate components: (1) robotic load handlers that move along tracks to retrieve containers from stacks, and (2) a conveyor system that sequences and transports containers to dispatch points. This segmentation allows the robotic handlers to focus only on retrieval while the conveyor handles sequencing, reducing the complexity and cost of the robotic systems while maintaining high storage density.
Solution Approach 2:
The conveyor system acts as an intermediary between the robotic load handlers and the dispatch points. Instead of requiring robotic handlers to perform complex sequencing operations, the conveyor mediates by receiving containers from handlers and automatically sequencing them in the predetermined order required for dispatch, thereby simplifying the robotic systems and reducing costs.
2Adaptability or versatility
If containers are retrieved and combined for customer orders, then order fulfillment capability is improved, but sequencing containers for transference between storage systems becomes complex and time-consuming
Solution Approach 1:
The conveyor system is configured to sequence containers in a predetermined order based on future dispatch requirements before they are actually needed. This preliminary sequencing action eliminates the need for time-consuming re-sequencing operations when containers need to be transferred between storage systems or dispatched, thereby reducing loss of time while maintaining versatile order fulfillment capability.
Solution Approach 2:
The conveyor system operates continuously to sequence and transport containers, ensuring that sequencing is an ongoing process rather than a batch operation. This continuous action allows containers to be sequenced in real-time as they are retrieved, eliminating idle time and ensuring that containers are always ready for immediate transfer or dispatch, thereby reducing sequencing time while maintaining adaptability.
3Adaptability or versatility
If load handlers move along tracks to access containers, then container retrieval flexibility is improved, but system congestion increases and throughput is reduced
Solution Approach 1:
The system segments the container handling process into retrieval operations (performed by robotic load handlers moving along tracks) and sequencing/transport operations (performed by the conveyor system). This segmentation allows robotic handlers to focus solely on flexible retrieval from various stack locations while the conveyor handles the sequencing and transport, thereby maintaining retrieval flexibility while improving overall system throughput by eliminating congestion at dispatch points.
Data Source
Figure 1
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Figure 3a
AI summary
A sequencing system for a robotic storage and picking system. The storage system comprises a plurality of containers disposed in stacks 10 beneath a grid 22, the grid comprising a first set of tracks and second set of tracks, the first and second sets of tracks being disposed substantially perpendicular to each other. The storage system 1 comprises a plurality of load handling devices operable on the grid, the load handling devices 30 lifting and depositing containers from and to the stacks. A portion of the grid 22 extends over a series of conveyor belts 42. The load handling devices being capable of depositing containers on to the conveyor belts into predetermined positions, the positions being fillable in any random order and multiple positions being fillable at any one time.