Pallet Load Generator Optimizing Store Distribution

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Solution Overview

Problem

Current material handling systems face challenges in optimizing the loading of goods onto pallets for efficient unloading and distribution in retail stores, as they often require customized handling methods that vary by customer, leading to inefficiencies and increased operational complexity.

Innovation Solution

The system employs a computational method to plan and build 'store-friendly' pallet loads by combining products from physically close aisles and considering retail store preferences, using automated machinery and manual processes to create pallets that align with store-specific unloading methods, such as clustered, adjacent, or mixed-mode distribution strategies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If customized handling methods are used for each customer's pallet loading requirements, then the adaptability to different customer preferences is improved, but the device complexity and operational complexity increase

Engineering Contradiction:

Improveadaptability to customer preferencesVSAvoidoperational complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system implements a universal pallet building methodology that can handle multiple customer preferences (clustered, adjacent, and mixed-mode distribution strategies) through a single integrated platform. The system uses a common data structure and algorithm framework that adapts to different customer requirements without requiring separate specialized systems for each preference type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system changes parameters such as aisle sequence, product grouping, and pallet configuration to accommodate different customer preferences. By adjusting these parameters within a unified system architecture, the system achieves adaptability without increasing operational complexity, as the same core algorithm handles different parameter configurations.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If more pallets are used to accommodate diverse customer preferences, then the adaptability is improved, but the loss of substance and storage efficiency worsen

Engineering Contradiction:

Improvecustomer preference accommodationVSAvoidstorage efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The system performs preliminary planning and optimization of pallet configurations before actual pallet building. By pre-calculating the most efficient pallet arrangements that satisfy customer preferences, the system minimizes wasted space and reduces the total number of pallets needed, thereby improving storage efficiency while maintaining adaptability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses optimization algorithms that may initially generate more pallet configurations than necessary, then refines these to eliminate excess pallets. This approach ensures that customer preferences are fully accommodated while minimizing the final number of pallets used, balancing adaptability with storage efficiency.

Inventive Principle:

Principle #16Partial or excessive action

3Productivity

If automated machinery is used to build pallets, then the productivity is improved, but the ease of operation and flexibility worsen

Engineering Contradiction:

Improvepallet building speedVSAvoidsystem flexibility

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The automated pallet building system is designed with dynamic reconfigurability, allowing it to adapt to different customer preferences and product types. The system can change its operating parameters and configuration on-the-fly, maintaining flexibility while preserving the high productivity benefits of automation. This is achieved through programmable control systems that can be quickly reconfigured via software rather than physical modifications.

Inventive Principle:

Principle #15Dynamics

4Productivity

If optimization algorithms are used to minimize pallet number, then the productivity is improved, but the computational time and complexity increase

Engineering Contradiction:

Improvepallet utilization efficiencyVSAvoidcomputational time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system employs optimization algorithms that provide near-optimal solutions rather than requiring complete exhaustive search. By accepting solutions that are sufficiently good (rather than perfectly optimal), the system achieves high pallet utilization efficiency without the prohibitive computational time that would be required for exhaustive optimization of all possible configurations.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS20230182306A1Material handling system and method therefor

Publication Date: 2023.06.15 SYMBOTIC LLC

AI summary

A material handling system, for handling and placing packages onto pallets destined for an order store, including a storage array, an automated package transport system, an automated palletizer, and a controller operably connected to the automated palletizer, the controller being programmed with a pallet load generator with at least one pallet to order store affinity characteristic, for a predetermined method of pallet load packages distribution at the order store, the pallet load generator being configured so that a pallet load is formed by the automated palletizer of packages arranged in the pallet load embodying the at least one pallet to order store affinity characteristic.