Robotic Break Pack System for Automated Order Fulfillment

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Solution Overview

Problem

Manual unpacking and packing of products at distribution centers are time-consuming and prone to human errors, leading to increased operational costs and customer losses for retailers.

Innovation Solution

Implementing a system that uses robotic arms controlled by an electronic inventory management device for automated order fulfillment, including de-palletizing, stocking, picking, and packing, with verification processes to ensure accurate product placement and orientation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual unpacking and packing operations are used at distribution centers, then workers can handle products flexibly, but the process becomes time-consuming and error-prone, increasing operational costs

Engineering Contradiction:

ImproveFlexibility in product handlingVSAvoidOrder fulfillment speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual mechanical operations with an automated robotic system that uses computer vision and robotic arms to perform picking and packing tasks. The system substitutes human workers with machines that can operate continuously at high speed without errors, directly resolving the contradiction between operational flexibility and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic system autonomously performs the entire picking and packing process without human intervention. The system self-manages product identification, selection, packaging, and verification, eliminating the need for manual labor while maintaining high productivity and accuracy throughout the fulfillment process.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual operations are used for order fulfillment, then workers can adapt to different products, but human errors lead to improper product delivery, increasing operational costs and customer losses

Engineering Contradiction:

ImproveAbility to handle different productsVSAvoidAccuracy of product delivery

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system incorporates verification processes that provide feedback on product selection and packaging accuracy. Sensors and vision systems continuously monitor the robotic operations to ensure correct products are picked and properly packaged, eliminating human errors while maintaining adaptability to handle diverse product types through programmable instructions.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces human workers with a robotic system that uses computer vision and automated control to identify and handle different products. The system adapts to various product types through software programming rather than human learning, while maintaining consistent accuracy without the errors associated with manual operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated robotic systems are implemented for order fulfillment, then operational efficiency and accuracy are improved, but system complexity and initial investment increase

Engineering Contradiction:

ImproveOrder fulfillment speedVSAvoidSystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The robotic system is designed as a multi-functional platform that can handle various product types, packaging formats, and fulfillment scenarios through reconfigurable end effectors and programmable instructions. This universality allows the system to maintain high productivity across different tasks while reducing the need for multiple specialized systems, thereby managing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system introduces an electronic inventory management device as an intermediary that coordinates between the order processing server and the robotic components. This intermediary manages the complexity by centralizing control logic, handling product identification, and coordinating robotic actions, making the overall system more manageable despite its inherent complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10773891B2Order fulfillment system with robotic break pack

Publication Date: 2020.09.15 WALMART APOLLO LLC

AI summary

In some embodiments, methods and systems for fulfilling consumer orders are provided. A stocking station includes at least one robotic stocking arm configured to unload a product from a first receptacle and to place the unloaded product onto a storage shelf, and a first picking station includes a first robotic picking arm configured to pick a first product from the storage shelf and to load the first product picked from the storage shelf into a second receptacle for delivery to a consumer. An empty receptacle placement station includes at least one robotic placing arm configured to place an empty second receptacle onto a packing conveyor configured to transport the empty second receptacle toward the first picking station for loading of the first product into the empty second receptacle. An electronic inventory management device transmits a signal the empty receptacle placement station and the first robotic picking arm.