Gravity-Assisted Container Unloading for Automated Retrieval
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Solution Overview
Problem
Unloading the contents of containers in an automated storage and retrieval system is time-consuming, especially in high-demand situations like grocery shopping, leading to increased labor costs due to the need for multiple pickers to handle numerous orders quickly.
Innovation Solution
A system and method utilizing a container handling vehicle with orientation sensors and a central control unit, combined with a container tipping device and unloading station, allows for the contents to be emptied by gravity through mechanisms like helical paths, rails, or biased wheels, ensuring controlled and efficient unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual picking methods are used to unload container contents, then labor flexibility is maintained, but unloading speed is slow and labor costs increase
Solution Approach 1:
The system divides the unloading process into distinct functional modules: container transport vehicle, tipping device with hydraulic actuators, item collection conveyors, and sorting mechanisms. Each module operates independently but coordinates through central control, enabling high-speed automated unloading while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The patent replaces manual mechanical picking operations with an automated mechanical system featuring motorized container tipping, hydraulic actuation, and conveyor-based item transport. This substitution eliminates human labor from the unloading process, achieving high productivity through automated mechanical operations controlled by computer systems
2Productivity
If multiple pickers are deployed to handle numerous orders quickly, then order fulfillment speed increases, but labor costs increase
Solution Approach 1:
The system enables self-service automated unloading where the container handling vehicle and tipping mechanism automatically extract and transport items without human intervention. The centralized control system autonomously manages the entire unloading process, replacing multiple human pickers with an autonomous mechanical system that maintains high order fulfillment speed while eliminating labor requirements
Solution Approach 2:
The patent transforms the unloading process from manual to automated by changing key operational parameters: speed increases through motorized tipping and conveyor systems, while labor quantity drops to zero. The system maintains flexibility through programmable control that can adapt to different order requirements, effectively replacing human labor with automated parameter-controlled operations
3Productivity
If containers are stacked in high storage columns, then storage density increases, but access time to lower containers increases
Solution Approach 1:
The system performs preliminary action by transporting containers to a dedicated tipping station before unloading. The container handling vehicle brings containers from any storage position directly to the tipping point, where items are rapidly discharged via gravity-assisted tipping. This preliminary positioning eliminates the need for sequential container removal from stacked columns, maintaining high storage density while enabling rapid access to containers at any level
Solution Approach 2:
The patent extracts the unloading function from the storage structure itself by implementing a separate, dedicated tipping station. Instead of accessing items directly from stacked containers in storage columns, the system extracts containers to a specialized unloading area where rapid item discharge occurs through controlled tipping. This separation maintains high storage density in columns while enabling fast access through the extracted unloading process
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 faster item retrieval from storage systems.
Implementation Method 1
a container tipping device that tips the container around at least one axis, emptying the content
Data Source
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 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 which is perpendicular to the first direction, 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.