Container Tipping Unloading for Faster Gravity-Based Item Emptying
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Solution Overview
Problem
Existing automated storage and retrieval systems face inefficiencies in unloading items from containers, particularly in high-volume scenarios like grocery shopping, leading to increased labor costs and time consumption due to the need for multiple pickers and slow item retrieval processes.
Innovation Solution
A system and method utilizing a container handling vehicle equipped with an orientation sensor and a central control unit, combined with a container tipping device that tips the container around an axis to empty its contents by gravity, guided by a helical path or rail system, and optionally using compartmentalized containers with controlled lids or robotic arms for precise unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual picking methods are used for unloading items from containers, then flexibility in item selection is maintained, but labor costs and time consumption increase significantly
Solution Approach 1:
The container is equipped with sensors and actuators that enable it to automatically identify, locate, and dispense items without external intervention. The container serves itself by using its own onboard resources (sensors, processors, dispensing mechanisms) to complete the unloading operation, thereby achieving high productivity without requiring complex external picking systems or human labor.
Solution Approach 2:
Manual mechanical picking operations are replaced with an automated electronic control system. The container uses sensors to detect items, a processor to determine dispensing logic, and automated actuators to release items, substituting the mechanical human hand-picking process with an integrated electronic-mechanical system that operates autonomously.
2Productivity
If multiple pickers are deployed to handle high-volume unloading scenarios, then unloading capacity increases, but operational costs and coordination complexity increase
Solution Approach 1:
The functions of multiple human pickers (item identification, location tracking, item retrieval, and dispensing) are merged into a single integrated automated system within the container. This consolidation eliminates the need for multiple workers and their coordination, achieving high unloading capacity through a unified autonomous system that processes all tasks simultaneously without inter-personal coordination delays.
Solution Approach 2:
The automated container system operates continuously without interruption, processing multiple item requests in sequence without the breaks, coordination delays, or physical limitations that affect human pickers. The system maintains continuous operational capability, rapidly handling high-volume unloading scenarios without loss of time to coordination or human fatigue.
3Productivity
If traditional storage and retrieval systems are used, then item storage is achieved, but retrieval speed and efficiency are insufficient for high-volume scenarios
Solution Approach 1:
The container pre-identifies and pre-positions items for dispensing using onboard sensors and processors before actual retrieval is needed. Item locations are mapped and organized in advance, and the system prepares dispensing sequences beforehand, enabling rapid retrieval operations without time-consuming search or manual organization during the actual unloading process.
Solution Approach 2:
An onboard computer system acts as an intermediary between the stored items and the external environment. This intermediary processes retrieval requests, coordinates with sensors to locate items, controls actuators for dispensing, and manages the overall retrieval operation, thereby achieving high retrieval speed while maintaining operational simplicity through centralized intelligent control.
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
Facilitates rapid and controlled unloading of container contents, reducing labor requirements and operational costs by enabling efficient item retrieval and distribution, suitable for high-volume environments.
Implementation Method 1
a container tipping device that tips the container around an axis to empty its contents by gravity
Data Source
Figure 1
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Figure 4
AI summary
System and method for unloading a container of its content, comprising an automated storage and retrieval system, wherein the system comprises a rail system comprising a first set of parallel rails arranged to guide movement of a container handling vehicle in a first direction (X) across the top of a framework structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicle in a second direction (Y) which is perpendicular to the first direction (X), the first and second sets of parallel rails dividing the rail system into a plurality of grid cells, the framework structure comprises upright members and horizontal members, at least one container handling vehicle configured to operate on the rail system, wherein the at least one container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of the sensor in a three-dimensional cartesian reference system, a central control unit configured to receive, transmit and process data signals of the container handling vehicle and to receive and process data signals of the sensor, at least one container comprised of four side walls and a bottom creating an open box structure, means for transporting the container to an unloading station where the content of the container is emptied by gravity wherein the unloading station comprises a container tipping device that tips the container around at least one axis, emptying the content.