Multi-Zone Robotic Tote Handling for Chilled and Frozen Goods
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Solution Overview
Problem
Automated retail supply chain systems face challenges in maintaining different temperature zones for storing and transporting products, particularly in handling chilled and frozen goods, as existing systems often require separate robots and workstations for each temperature range, leading to inefficiencies and potential condensation issues.
Innovation Solution
An automated order fulfillment system with multiple temperature zones, including ambient, chilled, and frozen areas, utilizing autonomous robotic vehicles (A-Bots and C-Bots) and containers designed for temperature-specific operations, along with a distributed temperature regulation system that manages temperature and humidity to prevent condensation, allowing robots and totes to transition seamlessly between zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate robots and workstations are used for each temperature range (ambient, chilled, frozen), then temperature control reliability is improved, but device complexity and operational efficiency deteriorate
Solution Approach 1:
The patent applies universality by designing a single robotic vehicle that can operate across multiple temperature zones (ambient, chilled, and frozen). The robot is equipped with temperature-controlled containers and can transition between zones without requiring separate specialized robots for each temperature range, thereby reducing system complexity while maintaining temperature control reliability.
Solution Approach 2:
The system implements dynamics by allowing the robotic vehicle to dynamically adapt to different temperature environments. The robot can adjust its operational parameters and container temperature settings based on the zone it is currently operating in, enabling flexible operation across varying thermal conditions without compromising product integrity.
2Reliability
If separate robots and workstations are used for each temperature range, then temperature control reliability is improved, but productivity and operational efficiency deteriorate
Solution Approach 1:
By creating a universal robotic vehicle that can service multiple temperature zones, the system eliminates the need for product transfer between separate specialized robots. This multi-functional approach allows a single robot to pick, transport, and deliver products across ambient, chilled, and frozen zones continuously, significantly improving operational efficiency and productivity.
Solution Approach 2:
The robotic vehicle enables continuous operation across temperature zones without interruption. The robot can maintain its operational sequence by transitioning between zones while keeping products at appropriate temperatures, eliminating idle time and transfer delays that would occur in a system with separate specialized robots for each zone.
3Productivity
If robots transition between temperature zones, then system flexibility and productivity are improved, but condensation and humidity control issues arise
Solution Approach 1:
The patent introduces an intermediary temperature-controlled container system that mediates between different temperature zones. The robot uses insulated containers with active temperature control as intermediaries to transfer products between zones, preventing direct exposure to temperature differentials that cause condensation. The container acts as a buffer, maintaining product temperature stability during transitions.
Solution Approach 2:
The system dynamically adjusts temperature parameters during zone transitions. The robotic vehicle monitors and adjusts container temperature settings based on the destination zone, gradually acclimating products to new temperature environments to prevent rapid condensation formation. Humidity control parameters are also adjusted to maintain optimal conditions during transitions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient storage and retrieval of temperature-sensitive items by allowing robots and containers to operate across multiple temperature zones, reducing condensation and energy consumption while maintaining product freshness, thereby enhancing the overall efficiency and flexibility of the supply chain.
Implementation Method 1
a cooling system configured to cool the plurality of containers to the different temperatures
Implementation Method 2
cooling fluid from the cooling system entering the liner from the inlet port to cool eaches within the container
Implementation Method 3
a distributed temperature regulation system that manages temperature and humidity to prevent condensation
Data Source
AI summary
An automated order fulfillment system is disclosed having different temperature zones and robots and containers capable of and/or configured to work in these different temperature zones.