Conveyor Logic for Balancing Empty Tote Distribution
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Solution Overview
Problem
There is a lack of automated systems for efficiently managing and distributing empty totes across multiple filling or picking areas in warehouses and storage facilities, leading to manual labor inefficiencies and imbalances in tote availability.
Innovation Solution
A conveyor system with sensors and a control circuit that directs empty totes along conveyor lines to areas of need, using buffer components to redistribute totes from one filling station to another or to storage when capacity thresholds are met, ensuring balanced distribution and reducing labor requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual labor is used to gather and transport empty totes between picking areas, then flexibility in tote distribution is maintained, but labor hours and operational efficiency deteriorate
Solution Approach 1:
The system enables self-service through automated sensors that detect tote needs at picking areas and autonomously direct empty totes along conveyor lines to areas of need, eliminating manual labor while maintaining distribution flexibility
Solution Approach 2:
The system implements feedback mechanisms where sensors monitor tote inventory levels at various picking areas and automatically adjust tote distribution in real-time, allowing the system to respond dynamically to changing operational needs without human intervention
2Device complexity
If empty totes are stacked at a single destination and removed as a stack, then device complexity is reduced, but tote availability at multiple picking areas deteriorates
Solution Approach 1:
The system segments the tote distribution function by providing separate conveyor line paths to multiple picking areas, allowing totes to be directed to specific locations based on real-time needs rather than consolidating all totes at a single stacking location
Solution Approach 2:
The system adds a temporal dimension to tote distribution by using sensors to detect needs in real-time and dynamically routing totes along different conveyor paths, transforming the static single-destination stacking approach into a dynamic multi-destination distribution network
3Productivity
If automated conveyor systems are implemented to transport totes, then productivity increases, but device complexity and initial investment deteriorate
Solution Approach 1:
The conveyor lines are designed with universal functionality to handle both full totes traveling from picking areas to consolidation areas and empty totes returning to picking areas, eliminating the need for separate dedicated conveyor systems for each direction and reducing overall device complexity
Solution Approach 2:
The system merges the functions of tote collection, sorting, and redistribution into a single integrated conveyor network with buffer components, combining multiple operations that would traditionally require separate systems into one cohesive automated infrastructure
Data Source
AI summary
In some embodiments, apparatuses and methods are provided herein useful to automatically balance and buffer the return of empty containers or other totes to a plurality of areas. In some embodiments, a control circuit employs a logic system in which empty totes are directed along primary, secondary, or tertiary paths depending on information gathered from sensors regarding the availability of space for empty totes at a plurality of potential destinations. In this way, the return of empty totes to one or more points of origin may be buffered to balance the number of empty totes in one or more areas.