Modular Warehouse Bins with Self-Supporting Stacks
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Solution Overview
Problem
Current automated order fulfillment systems in warehouses are not comprehensive and fail to provide flexible, redundant, scalable, error-free services with optimal space utilization, as they often rely on manual processes or complex structures, and existing automated solutions are not effective in managing modular storage efficiently.
Innovation Solution
A modular warehouse system comprising stackable bins with horizontal and vertical attachment means for self-supporting stacks, bin retrieval robots, carts for transportation, and a computing device for inventory management, traffic control, and simulation capabilities, allowing for flexible configuration and real-time reorganization without permanent structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual or semi-manual processes are used for order fulfillment, then operational flexibility is maintained, but productivity and error-free service are compromised
Solution Approach 1:
The system segments the warehouse into modular zones with stackable bins that can be independently configured. Each bin stack is a self-contained unit that can be retrieved and repositioned without affecting other stacks, enabling flexible reconfiguration while maintaining automated high-speed retrieval operations through multiple independent robot stations.
Solution Approach 2:
The bin stacks are designed to be dynamic rather than static - they can be repositioned, reconfigured, and restacked on demand. The system transitions from fixed shelving to movable bin stacks that can be dynamically reallocated based on order requirements, combining the flexibility of manual reconfiguration with automated retrieval speed.
2Productivity
If automated retrieval systems are implemented, then productivity increases, but device complexity and space utilization requirements worsen
Solution Approach 1:
The system extracts the retrieval function from complex fixed rack structures and assigns it to mobile robot units. Instead of having automated mechanisms built into permanent shelving, independent robot stations are deployed that can move to any bin stack location, simplifying the overall system architecture while maintaining high retrieval speeds through specialized robotic end-effectors.
Solution Approach 2:
The robot stations are designed as universal, multi-functional units that can retrieve bins from any location in the warehouse. Rather than having dedicated retrieval mechanisms for each rack position, a single robot design can service any bin stack anywhere in the facility, reducing device complexity through standardization while maintaining productivity through flexible deployment.
3Volume of stationary object
If fixed shelving structures are used, then space utilization is optimized, but adaptability and reconfiguration capability are reduced
Solution Approach 1:
The storage system is segmented into discrete bin stacks rather than continuous fixed shelving. Each bin stack is an independent modular unit that can be individually repositioned, removed, or reconfigured without affecting the overall warehouse layout. This segmentation enables high space utilization through compact stacking while maintaining adaptability through easy reconfiguration of individual modules.
Solution Approach 2:
The system enables parameter changes in warehouse configuration by allowing bin stacks to be dynamically repositioned and reconfigured. The physical parameters of the storage layout (positions, orientations, groupings) can be changed on demand to adapt to different order patterns and product mixes, while maintaining optimal space utilization through efficient stacking arrangements.
4Volume of stationary object
If complex rack structures are created for space utilization, then storage density increases, but ease of operation and retrieval flexibility are compromised
Solution Approach 1:
The system extracts the retrieval operation from the fixed rack structure itself and assigns it to mobile robot units. Instead of having complex mechanisms built into the shelving for retrieving items from any position, independent robot stations are deployed that can travel to and retrieve any bin stack, simplifying the rack structure to basic stacking while maintaining retrieval flexibility through robotic automation.
Data Source
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AI summary
Systems and methods for a modular warehouse system comprising: at least two modular stackable bins wherein said bins does not require structural support and may allow retrieval of at least one of said bins, regardless of its location in the pile, without changing said pile's order; at least two bin retrieval robots; at least one non-transitory computer-readable medium storing processor executable instructions on a computing device for warehouse management.