Modular Inventory Vehicles for Dynamic Warehouse Slotting

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Solution Overview

Problem

Modern material handling systems in warehouses and distribution centers face challenges in efficiently managing inventory as they scale, leading to increased costs and complexity, with existing automation solutions becoming cost-prohibitive as they reach a point of diminishing returns.

Innovation Solution

The implementation of modular automated vehicles that can interact with functional accessory modules (FAMs) to perform various inventory management tasks, allowing for the adaptation to increasing complexity and demand by substituting or adding new FAMs, enabling scalable solutions for growing inventory differentiation and higher throughput requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional warehouse automation systems are expanded incrementally to accommodate growing inventory and throughput requirements, then capacity and functionality are improved, but cost and complexity increase to the point of diminishing returns

Engineering Contradiction:

Improvethroughput capacityVSAvoidautomation infrastructure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the warehouse automation infrastructure into modular robotic units, each capable of independent operation. These segmented robots can be individually deployed or combined based on throughput requirements, avoiding the need to expand complex monolithic automation systems. Each robot handles specific tasks (picking, packing, sorting) and can be added incrementally without proportionally increasing overall system complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic units are designed with universal capabilities to perform multiple inventory management tasks including picking, packing, sorting, and replenishment. This multi-functionality allows a single robot design to handle diverse operations across different zones, reducing the need for specialized equipment and thereby controlling complexity while maintaining productivity flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the facility expands automation infrastructure to handle higher SKU counts and order volumes, then productivity increases, but the cost becomes prohibitive

Engineering Contradiction:

Improveorder picking volumeVSAvoidimplementation cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The system employs relatively simple, standardized robotic units that can be manufactured at lower cost compared to complex traditional automation equipment. These robots are designed to be economically replaceable and can be deployed in large numbers to handle high order volumes, reducing the prohibitive cost barrier while maintaining productivity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The system allows dynamic scaling where robotic units can be added, removed, or reconfigured based on fluctuating order volumes and SKU counts. This dynamic approach enables the facility to match automation capacity precisely to demand, avoiding over-investment in fixed infrastructure and reducing overall implementation costs.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If traditional automation infrastructure is replaced with a completely new automation platform to achieve further gains, then functionality is improved, but cost and disruption increase significantly

Engineering Contradiction:

Improvesystem functionalityVSAvoidinfrastructure replacement complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Instead of replacing the entire automation infrastructure at once, the system introduces new robotic units that operate independently alongside existing equipment. This segmented approach allows incremental functionality improvements without requiring complete infrastructure replacement, thereby reducing both cost and operational disruption while enhancing adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic units serve as intermediary elements that bridge traditional automation infrastructure and modern flexible automation needs. These robots can interface with existing conveyors, storage systems, and order management platforms, enabling functionality enhancements without forcing a complete infrastructure overhaul and reducing implementation complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11827452B2Systems and methods for dynamically managing the location of inventory items in an inventory management facility

Publication Date: 2023.11.28 OPEX CORP

AI summary

An inventory management system includes pick stations, automated vehicles having an onboard power source, a first drive system configured to horizontally displace the vehicle, a second drive system configured to vertically displace the vehicle along a guide system, and a platform for supporting an item during displacement of the vehicle. A first plurality of storage locations store inventory items at a first zone of vehicle operation and a second plurality of storage areas store inventory items at a second zone of vehicle operation. A first pick station is closer to the first storage locations than to the second storage locations, Vehicles are configured to transfer a selected item from one of the second plurality of storage locations to the first pick station or to transfer the selected item from the second plurality of storage locations to the first plurality of storage locations.