Container Topping-Off Control for Retail AS/RS Space Utilization

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Solution Overview

Problem

Existing automated storage and retrieval systems (AS/RS) face inefficiencies in managing product inventory, leading to suboptimal storage container utilization and increased costs due to low tote utilization during decanting processes.

Innovation Solution

Implementing a system that utilizes container-packing algorithms to identify and prioritize containers with the lowest utilization for topping off with new products, considering factors like weight, distance, and energy cost, and optimizing product stacking configurations to maximize space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If products are stored in individual storage locations rather than consolidated, then product accessibility and retrieval speed improve, but storage space utilization deteriorates

Engineering Contradiction:

Improveretrieval speedVSAvoidstorage space utilization

Core Design Contradiction:

SpeedVSVolume of moving object

Solution Approach 1:

The system segments storage into two levels: container-level segmentation for rapid retrieval (containers are moved as units to designated locations) and product-level segmentation within containers (products are individually organized and accessible within each container). This allows the system to maintain fast retrieval speeds by moving entire containers while improving space utilization through efficient product arrangement within containers.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements nesting by placing multiple products within single containers, which are then placed in storage locations. This nested structure allows the system to retrieve entire containers quickly (improving retrieval speed) while maximizing the use of container space through optimized product packing (improving storage utilization).

Inventive Principle:

Principle #7Nested doll (Nesting)

2Volume of moving object

If containers are frequently moved to decanting stations for topping off, then storage utilization improves, but energy consumption and operational complexity increase

Engineering Contradiction:

Improvecontainer utilizationVSAvoidenergy cost

Core Design Contradiction:

Volume of moving objectVSUse of energy by moving object

Solution Approach 1:

The system performs preliminary actions by proactively identifying containers that need topping off before they become empty, calculating optimal routes and consolidating multiple container movements into single trips. This reduces the frequency and energy cost of container movements while maintaining high utilization levels.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors container utilization levels and provides feedback to the control circuit, which adjusts container movement schedules and routes dynamically. This feedback mechanism ensures containers are topped off only when necessary, optimizing energy consumption while maintaining efficient space utilization.

Inventive Principle:

Principle #23Feedback

3Productivity

If multiple products from a single shipment are placed in one container, then storage efficiency improves, but product variety and customer order fulfillment flexibility decrease

Engineering Contradiction:

Improvestorage efficiencyVSAvoidorder fulfillment flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system segments containers into product-specific compartments or zones within the container, allowing multiple different products to be stored in the same container without mixing. This maintains storage efficiency by consolidating multiple products per container while preserving order fulfillment flexibility by keeping products separately organized and easily accessible.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by assigning different organizational structures to different containers based on their contents and usage patterns. Containers holding products for similar orders are organized differently from those holding diverse products, optimizing both storage efficiency and retrieval flexibility for each specific case.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12475432B2Systems and methods for optimizing space utilization of containers at retail storage facilities

Publication Date: 2025.11.18 WALMART APOLLO LLC

AI summary

Automated storage and retrieval systems for managing storage of inventory at a retail facility include a storage structure with storage locations configured to store containers that contain retail products, and a container transport system that transports the containers between the storage locations and a decanting station. A processor-based control circuit identifies a group of eligible containers for topping off (i.e., adding additional products) and determines a utilization value for each of the eligible containers. The control circuit determines an effort value for each of the eligible containers and ranks the eligible containers based on the utilization value and the effort value for each container. The control circuit then selects a subgroup from the eligible containers based on the rankings and causes the container transport system to transport each container in the subgroup of eligible containers from its respective storage location in the storage structure to the decanting station.