Integrated Storage Racks with Lifts for Order Fulfillment
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Solution Overview
Problem
Current order fulfillment methods in storage facilities face high technical complexity and space requirements, leading to increased costs and reduced throughput due to the need for complex front-zone operations and dedicated sorters/sequencers.
Innovation Solution
The method involves connecting lifts directly to picking stations and using separate storage areas with integrated lifts for parallel storage and retrieval operations, eliminating the need for a front zone and allowing zone routing and sorting within the storage itself, with cross-conveyance locations inside the racking units to transfer units between aisles, reducing the need for external sorting and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a front zone with dedicated sorters and sequencers is used to coordinate AS/RS and control goods flow, then sequencing and sorting accuracy is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent removes the front zone with its dedicated sorters and sequencers from the system. Instead, storage racks are positioned directly adjacent to the picking station, eliminating the need for intermediate sorting and sequencing equipment while maintaining operational accuracy.
Solution Approach 2:
The patent combines the storage function and the picking function into a single integrated area. Storage racks are placed directly next to the picking station, merging what were previously separate zones (storage area and front zone) into one unified space, thereby reducing overall system complexity.
2Productivity
If a front zone is used for AS/RS coordination and goods flow control, then retrieval sequencing is improved, but space requirements and costs increase
Solution Approach 1:
The patent eliminates the front zone entirely by positioning storage racks directly adjacent to the picking station. This removes the need for separate sorting and sequencing infrastructure, significantly reducing the space required for stationary objects while maintaining efficient retrieval sequencing through direct rack-to-station access.
3Manufacturing precision
If units are retrieved and rerouted through the front zone for sorting, then order fulfillment accuracy is improved, but loss of time and throughput are reduced
Solution Approach 1:
The patent removes the front zone routing step from the process. Storage racks are positioned directly next to the picking station, allowing units to be retrieved and immediately placed into order containers without intermediate routing through a front zone, thereby reducing time loss while maintaining accuracy.
Solution Approach 2:
The patent segments the storage facility into multiple independent storage racks positioned directly at the picking station. Each rack can be independently accessed and retrieved from, eliminating the need for centralized front zone coordination and reducing retrieval time while maintaining order fulfillment accuracy.
Data Source
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AI summary
Method of order fulfilling by making order and/or product units (O, P) available from a storage facility (1) at a picking station (10) wherein the storage facility comprises: - a storage racking comprising a plurality of multilevel storage racks (R) in which order and/or product units (O, P) are stored, wherein the storage racks are disposed back-to-back in pairs and have an aisle between pairs; - at least one automatic storage and retrieval device of the shuttle type provided for each storage racking aisle, wherein the order and/or product units are stored and retrieved from the storage racks by the automatic storage and retrieval device; - wherein order and/or product units (O, P) are exchanged directly between two adjoining storage racks (R) from a source storage rack to an adjacent destination storage rack via cross conveyance locations in the storage racks themselves; - at least one picking station (10) for picking from product units into order units for fulfilling orders, to which order and/or product units are fed; - at least one lift (8B) integrated within the footprint of the storage racks (R) used to transfer the order units (O) vertically; wherein each lift (8A, 8B) is directly connected to a picking station (10) in a picking level and in that the order units are stored separately within the storage facility and the separate storages are connected to the picking station (10) by said lift.