Order Fulfillment Transfer System Buffering

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Solution Overview

Problem

Existing order fulfillment systems in online retail environments face inefficiencies due to the repeated movement of the same storage containers or bins to pick stations, leading to increased robotic load handler movements and congestion, which raises costs and reduces throughput.

Innovation Solution

A fulfillment system comprising a storage and retrieval system, a transfer system with a transfer station, and a pick station, where items are transferred from storage bins to a transfer station and then conveyed to pick stations via AGVs or conveyors, reducing the need for repeated container movements and load handler operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If robotic load handlers repeatedly move the same storage containers to pick stations, then order fulfillment can be completed, but system throughput decreases and congestion increases

Engineering Contradiction:

Improvesystem throughputVSAvoidtime for repeated container movements

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by having robotic load handlers deposit items into buffer locations before they are actually needed at pick stations. This advance preparation allows items to be staged and organized in advance, reducing the need for repeated container movements and improving overall system throughput while decreasing time loss.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If more robotic load handlers are added to reduce congestion, then order fulfillment speed improves, but capital costs increase

Engineering Contradiction:

Improveorder fulfillment speedVSAvoidnumber of robotic load handlers

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Buffer locations serve as intermediary storage spaces between the storage containers and pick stations. These buffers act as mediators that temporarily hold items, allowing the system to decouple the movement of storage containers from the picking process. This intermediary approach improves order fulfillment speed without requiring additional robotic load handlers, thereby avoiding increased capital costs.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If storage containers are kept at pick stations for quick access, then picking efficiency improves, but congestion increases

Engineering Contradiction:

Improvepicking efficiencyVSAvoidsystem throughput

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system segments the storage and picking functions by introducing separate buffer locations distinct from both storage containers and pick stations. This segmentation allows items to be pre-positioned in buffers for quick access during picking, improving picking efficiency. Simultaneously, storage containers can be returned to storage areas after depositing items, preventing congestion and maintaining high system throughput.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250115432A1System and method of order fulfilment

Publication Date: 2025.04.10 OCADO INNOVATION LTD

AI summary

A system and method of order fulfilment is described. The system comprises a storage and retrieval system, a transfer system and at least one pick station. The transfer system further comprises conveyance means disposed between the storage and retrieval system and the pick station such that items delivered to the transfer system from the storage and retrieval system may be conveyed to the pick stations independently of the normal operation of the pick station.