Inventory Handling Station Assembly for Flexible Bin Throughput
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Solution Overview
Problem
Existing storage and retrieval systems struggle to fulfill customer orders for immediate dispatch, particularly for small staple items and impulsive purchases, as they lack flexibility and are not suitable for unplanned orders, and require dedicated grid columns for access stations, limiting their adaptability and efficiency.
Innovation Solution
A modular, standalone inventory handling station assembly that includes a supply zone, access station, buffer zone, and conveyor system, which can be retrofitted to existing grid frameworks, allowing flexible operation as both a pick and restock station, with a vertical chute and bin lift device to manage container flow and increase throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dedicated access station with dedicated grid columns is used, then order fulfillment capability is improved, but system flexibility and adaptability deteriorate
Solution Approach 1:
The access station is designed to serve multiple functions: it can fulfill customer orders by retrieving bins from storage columns, restock bins back into storage columns, and handle both pick and restock operations through the same station infrastructure. This multi-functionality eliminates the need for separate dedicated stations for different operations.
Solution Approach 2:
The system dynamically assigns storage columns to different functions based on operational needs. Storage columns can be dynamically designated as supply columns, restock columns, or a combination thereof, allowing the system to adapt its configuration without physical reconfiguration. The access station can handle different operational modes (pick, restock, or both) flexibly.
2Adaptability or versatility
If a modular standalone inventory handling station assembly is used, then system flexibility and ease of retrofitting are improved, but device complexity increases
Solution Approach 1:
The inventory handling station assembly is divided into distinct functional modules: the access station component, the bin lift device component, the conveyor system component, and the buffer zone component. Each module can be independently manufactured, tested, and installed, simplifying the overall retrofitting process while managing complexity through modular architecture.
Solution Approach 2:
The patent introduces intermediate components such as the buffer zone and conveyor system that mediate between the access station and the storage columns. These intermediary elements simplify the integration process by providing standardized interfaces and decoupling the complexity of different subsystems, making the overall system easier to retrofit.
3Productivity
If vertical chutes and bin lift devices are added to manage container flow, then throughput and productivity are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The bin lift device is designed to operate at standardized height levels that align with the grid framework structure. By establishing equipotential lifting levels, the system simplifies the integration of vertical transport with horizontal conveyor systems, reducing the need for complex adaptive mechanisms while maintaining high throughput.
Solution Approach 2:
The vertical chute system is designed to guide bins automatically using gravity and the existing grid framework structure. The chutes leverage the natural vertical paths created by the storage columns, requiring minimal active control mechanisms. Bins self-guide through the chutes with minimal intervention, reducing the complexity of the handling mechanisms while maintaining efficient throughput.
Data Source
AI summary
An inventory handling station assembly for a storage and retrieval system is disclosed. A grid framework structure includes a plurality of upright columns for one or more containers to be stacked, the plurality of upright columns being interconnected at their top ends by grid members which support first and second sets of tracks for a load handling device to move containers on the grid framework structure. A supply zone includes at least one vertical chute. A buffer zone vertically accumulates containers and includes at least one bin lift device. An access station is intermediate of the supply zone. A conveyor system conveys containers 10 from the supply zone to the buffer zone via the access station.