Multi-Speed Conveyor Storage for Fulfillment Buffering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In fulfillment centers, items often accumulate in storage areas due to discrepancies in work rates between different tasks, leading to inefficient use of space and difficulty in accessing items when needed.
Innovation Solution
A conveyor-based storage system where items are stored in a circuit and can be moved vertically between conveyors operating at different speeds, allowing for efficient buffering and access optimization through a conveyor control system that tracks item locations and coordinates movement between slower and faster conveyors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If items are stored in a designated storage area on the floor or shelves, then a buffer is provided to allow agents to work without disruption, but storage space efficiency decreases and item accessibility deteriorates
Solution Approach 1:
The patent transitions from two-dimensional floor storage to three-dimensional vertical conveyor storage. Multiple conveyor circuits are stacked vertically, utilizing the vertical dimension to maximize storage capacity while maintaining efficient space utilization. Items are stored on conveyors at different heights and can be accessed by directing them to appropriate exit points.
Solution Approach 2:
The conveyor system acts as an intermediary between the storage area and the processing areas. Instead of directly accessing items on floor storage, the conveyor system mediates by transporting items to designated exit points, improving both accessibility and space utilization.
2Reliability
If items are stored on floor or shelves in a designated storage area, then buffering is achieved, but difficulty in finding and accessing items increases
Solution Approach 1:
The conveyor system provides self-service functionality where items are automatically transported to the appropriate exit points based on their destination requirements. The system autonomously manages item distribution without manual intervention, improving accessibility while maintaining buffer capacity.
Solution Approach 2:
The system uses tracking and control mechanisms to monitor item locations and conveyor statuses. This feedback enables the system to dynamically direct items to the most appropriate exit points, optimizing accessibility and ensuring items are delivered to the correct locations efficiently.
3Speed
If conveyors operate at different speeds, then access speed is optimized for different items, but system complexity increases
Solution Approach 1:
The conveyor system is divided into multiple independent circuits, each capable of operating at different speeds. This segmentation allows each conveyor to be optimized for its specific function and item type, achieving varied access speeds without requiring complex control of a single unified system.
Solution Approach 2:
The conveyor circuits are designed with variable speed capabilities, allowing the system to dynamically adjust speeds based on item priority, destination, and system conditions. This dynamic operation enables optimized access speeds while maintaining manageable system complexity through modular control.
Data Source
AI summary
Disclosed are various embodiments for a multiple speed, multiple conveyor storage system for items in a materials handling facility such as a fulfillment center. In one embodiment, the item storage system includes a first conveyor configured to operate at one speed, a second conveyor configured to operate at a different speed, and a transfer device configured to transfer items between the conveyors. The conveyors are each configured to store items in motion in a circuit arrangement.