Floating Receptacles for Non-Linear Order Sorting
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Solution Overview
Problem
Existing linear automated sorting mechanisms in materials handling facilities are limited by velocity, capacity, and flexibility, leading to high costs and inefficiencies, particularly when faced with increased inventory throughput demands, and are prone to gridlock due to insufficient offloading rates.
Innovation Solution
A non-linear, unit-level sortation system that uses 'floating' conveyance receptacles, each with a unique identifier, which are dynamically allocated to sorting stations, allowing for flexible routing and increased capacity without the need for additional automated equipment or space, enabling higher speeds and handling a wider variety of item sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If linear automated sorting mechanisms are used, then sorting can be performed automatically, but the system is limited in velocity, capacity, and flexibility
Solution Approach 1:
The system divides the sorting function into two independent parts: (1) a linear automated conveyance mechanism that transports receptacles, and (2) manual sorting stations where items are transferred to destination containers. This segmentation allows the automated portion to maintain high speed while the manual portion provides flexibility in handling diverse item types and sorting decisions.
Solution Approach 2:
Conveyance receptacles serve as intermediaries between the automated conveyance mechanism and the manual sorting stations. These receptacles are inducted onto the automated mechanism at one location and discharged at another, allowing the system to combine automated transport with manual sorting operations without direct integration.
2Productivity
If linear automated sorting mechanisms are used, then sorting capacity can be increased, but floor space requirements increase proportionally
Solution Approach 1:
The system transitions from a linear horizontal expansion model to a vertical utilization model. The automated conveyance mechanism operates in a loop that可以利用 vertical space and three-dimensional routing, allowing multiple sorting stations to access the same conveyance path at different locations and angles, thereby increasing capacity without proportional floor space increases.
Solution Approach 2:
The automated conveyance mechanism serves multiple sorting stations simultaneously, acting as a universal resource that can be accessed by various manual sorting stations. This multi-functional use of the conveyance system allows the same infrastructure to support increased sorting capacity across multiple destinations without requiring separate linear paths for each station.
3Speed
If sliding shoe sorters are used for high-speed sorting, then processing speed increases, but the system becomes prone to gridlock when offloading occurs at insufficient rate
Solution Approach 1:
The sorting action is extracted from the high-speed conveyance mechanism and relocated to manual sorting stations. The automated conveyance mechanism maintains high speed for transport, while the actual sorting operation occurs at stationary manual stations where items are removed from moving receptacles and placed in destination containers. This extraction eliminates the gridlock problem by decoupling high-speed transport from the offloading rate constraint.
Solution Approach 2:
The system dynamically adjusts the flow of receptacles through the automated conveyance mechanism based on the processing capacity of manual sorting stations. The loop-based conveyance allows receptacles to be held in circulation until ready for sorting, creating a dynamic buffer that prevents gridlock while maintaining high overall system speed.
Data Source
AI summary
Various embodiments of a method and apparatus for managing the allocation of items to processing stations in an order fulfillment process are described. The apparatus for managing the allocation of items to processing stations in an order fulfillment process may include a conveyance mechanism including at least one item inducted into the conveyance mechanism. The apparatus for managing the allocation of items to processing stations in an order fulfillment process may also include an item allocation component. The item allocation component may be configured to assign the item to a particular sorting station of a group of multiple sorting stations. The item allocation component may determine the particular sorting station to which the item is assigned based upon a determined quantity of other items located at the particular sorting station and a determined quantity of other items en route to the particular sorting station.