Order Picking Discharge Mechanism for Automated Container Transfer
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Solution Overview
Problem
Existing goods-to-person (GTP) order fulfillment systems require substantial manual labor and space for manually placing or replacing empty order containers, which is inefficient and labor-intensive.
Innovation Solution
An order fulfillment system with reusable order consolidation elements and a discharge mechanism that automatically transfers order items to a takeaway device, such as a segmented conveyor, eliminating the need for manual placement or replacement of order containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual placement of empty order containers is used, then operational flexibility is maintained, but labor requirements and space needs increase substantially
Solution Approach 1:
The system uses a discharge mechanism that automatically transfers order items from the consolidation element to the order container without requiring manual placement operations. The consolidation element self-discharges its contents when full, eliminating the need for operators to manually handle empty containers.
Solution Approach 2:
The manual mechanical operation of placing and removing empty containers is replaced by an automated discharge mechanism that uses mechanical forces (such as tilting or vibrating the consolidation element) to automatically transfer items to the container.
2Productivity
If automated discharge mechanism is implemented, then labor requirements are reduced, but device complexity increases
Solution Approach 1:
The consolidation element is designed with dynamic characteristics that enable automatic discharge. The element can be tilted, vibrated, or otherwise dynamically actuated to cause items to slide off onto the conveyor, replacing complex automated placement systems with simpler dynamic discharge mechanisms.
Solution Approach 2:
The discharge mechanism operates in periodic cycles - the consolidation element is filled, then periodically discharged by a simple actuation mechanism, then refilled. This periodic operation allows for simpler, less complex machinery compared to continuous automated container handling systems.
3Area of stationary object
If reusable consolidation elements are used, then space requirements are reduced, but transfer efficiency must be maintained
Solution Approach 1:
The order fulfillment process is segmented into distinct functional zones: the consolidation element for item accumulation, the discharge mechanism for transfer, and the conveyor for transport. This segmentation allows each component to be optimized independently, maintaining fast transfer speeds while requiring minimal space.
Solution Approach 2:
The discharge mechanism acts as an intermediary between the consolidation element and the conveyor system. It efficiently bridges the gap between these two components, enabling rapid item transfer without requiring additional space for intermediate handling areas.
Data Source
AI summary
A system and method for consolidating order items into individual or batch orders within an order fulfilment workstation and discharging the order items to a takeaway device, such as a trackable segmented conveyor. The system includes a temporary holding container at the workstation and a discharge mechanism to release or transfer the contents of the temporary container to the takeaway device. The system and method reduce or eliminate the process of an operator replenishing order transport containers to the workstation once a completed order container has dispatched from the workstation. Empty order containers are supplied the workstation via the takeaway device. The empty order container is positioned adjacent the temporary container such that the discharge mechanism may transfer the order items from the temporary container into the empty order container. The discharge mechanism may transfer the order items directly to the surface of the takeaway device.