Orthogonal Sortation Echelons for Mixed Goods Throughput
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Solution Overview
Problem
Conventional automated storage and retrieval systems are limited by a constrained exchange interface between supply containers and breakpack goods containers, which restricts throughput and efficiency in order fulfillment processes, particularly in mixed product container handling.
Innovation Solution
The implementation of orthogonal sortation echelons and breakpack modules within the automated storage and retrieval system, allowing for recursive sorting and reassembly of goods at various levels, and the use of container and goods bots for asynchronous transport and sorting, enabling flexible and efficient handling of mixed pallets and case units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional automated storage and retrieval systems use a constrained exchange interface between supply containers and breakpack goods containers, then the system structure is simplified, but the throughput and efficiency in order fulfillment processes are restricted
Solution Approach 1:
The system is divided into multiple independent echelons (first echelon with first container transfer deck, second echelon with second container transfer deck) that operate asynchronously. Each echelon handles specific sorting functions, allowing parallel processing of different product containers. This segmentation enables higher throughput by eliminating the bottleneck of a single constrained exchange interface while maintaining modular system architecture.
Solution Approach 2:
The system transitions from a single-level constrained exchange interface to a multi-level three-dimensional array storage structure with echelons at different heights. Product containers are transferred between echelons at different vertical levels, utilizing vertical space to increase throughput capacity without proportionally increasing horizontal footprint.
2Productivity
If conventional systems handle mixed product containers through manual breakpack stations, then labor flexibility is maintained, but time consumption and operational efficiency increase
Solution Approach 1:
The automated storage and retrieval system performs self-service by automatically retrieving product containers from the three-dimensional array storage structure and transporting them to appropriate echelons without manual intervention. The system autonomously sorts and assembles mixed product containers based on order requirements, eliminating the need for manual breakpack operations and significantly reducing time consumption.
Solution Approach 2:
Product containers are pre-sorted and staged in the first echelon before final assembly in the second echelon. This preliminary sorting action allows the system to prepare containers in advance based on predicted order requirements, reducing wait time during actual order fulfillment and improving overall efficiency.
3Adaptability or versatility
If conventional breakpack stations are arranged on a single common level, then the system layout is simplified, but the exchange interface between supply containers and breakpack goods containers is constrained
Solution Approach 1:
The breakpack function is segmented across multiple echelons at different vertical levels. The first echelon handles initial sorting and transfer, while the second echelon performs final assembly. This segmentation creates multiple exchange interfaces between supply containers and breakpack goods containers, increasing flexibility without requiring complex lateral rearrangements.
Solution Approach 2:
The system utilizes vertical dimension by arranging echelons at different heights within the three-dimensional array storage structure. This vertical arrangement provides multiple access points and exchange interfaces for container transfer, enhancing flexibility while maintaining a compact footprint compared to horizontal expansion.
Data Source
AI summary
A product order fulfillment system of mixed product units, the system includes a storage array, an automated transport system, with at least one asynchronous transport system, for level transport, and a lift for between level transport, communicably connected to the storage array so as to automatically retrieve and output, from an output of the storage array, product units distributed in cases in a common part of the storage array. The at least one asynchronous transport system, and the lift are configured so as to form more than one transport echelon, each echelon being communicably connected with the common part and the output, and each effecting orthogonal sortation, corresponding to the transport echelon, of the product units distributed in the common part, so that sorted mixed output product units of the corresponding transport echelon are in predetermined sequence.