Robotic Consolidation Station With Parallel Conveyor Pathways
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Solution Overview
Problem
Existing automated storage and retrieval systems face inefficiencies in consolidating items for customer orders, particularly when identical orders require sequential access to different storage containers.
Innovation Solution
A robotic consolidation station with a first conveyor pathway for picking and a second conveyor pathway for consolidation, equipped with a robotic picking arm to transfer items between storage containers, allowing for simultaneous operation and minimized movement of the robotic arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential access is used to retrieve items from different storage containers for identical orders, then the system can process orders one at a time, but the processing time increases and efficiency decreases
Solution Approach 1:
The consolidation station is divided into multiple independent conveyor pathways (first conveyor pathway for picking, second conveyor pathway for consolidation) that can operate simultaneously. This segmentation allows parallel processing of different order types, enabling the system to retrieve items from multiple storage containers at the same time rather than sequentially, thereby reducing processing time and increasing efficiency.
Solution Approach 2:
The system transitions from sequential one-dimensional processing to parallel multi-dimensional processing by introducing multiple conveyor pathways that operate simultaneously. The robotic picking arm moves between different conveyor pathways in a coordinated manner, enabling concurrent operations that reduce the total processing time for identical orders.
2Extent of automation
If a robotic picking arm is introduced to transfer items between storage containers, then automation increases and manual intervention is reduced, but device complexity increases
Solution Approach 1:
The robotic picking arm is designed as a multi-functional device that can operate on multiple conveyor pathways and perform various tasks including item picking, item transfer, and coordination with different conveyor systems. This universal design allows a single robotic arm to handle diverse operations without requiring separate specialized devices for each function, thereby increasing automation while controlling overall system complexity.
Solution Approach 2:
The robotic picking arm serves as an intermediary mechanism that coordinates between the first conveyor pathway (picking) and the second conveyor pathway (consolidation). This intermediary role allows the system to achieve high automation through a single coordinated robotic unit rather than requiring multiple independent automated systems, thus reducing the complexity increase that would otherwise result from full automation.
3Productivity
If multiple storage containers are accessed simultaneously for consolidation, then consolidation speed increases, but the required storage space and system footprint increase
Solution Approach 1:
The consolidation station is segmented into distinct functional zones with separate conveyor pathways for picking and consolidation operations. This spatial segmentation allows multiple storage containers to be accessed simultaneously in organized zones rather than requiring a large continuous storage area, thereby increasing consolidation speed while optimizing storage space utilization through structured layout.
Solution Approach 2:
The system utilizes vertical and horizontal spatial arrangement to organize multiple storage containers across different conveyor pathways. By distributing containers across multiple dimensions (different conveyor levels and positions) rather than concentrating them in a single large area, the system achieves high consolidation speed while maintaining compact storage footprint.
Data Source
AI summary
Storage containers may be stored a storage system including a framework structure. A robotic consolidation station for use in the storage system includes a first conveyor pathway for transfer of storage containers accommodating items to be picked, a second conveyor pathway for transfer of storage containers in which items are to be consolidated or have been consolidated, and a robotic picking arm arranged to reach the first conveyor pathway and the second conveyor pathway. Each of the first conveyor pathway and the second conveyor pathway includes a first end and a second end. Each first end may be operatively connected to a container outlet of the framework structure for transfer of storage containers from the framework structure and each second end may be operatively connected to a container inlet of the framework structure for transfer of storage containers into the framework structure. The first conveyor pathway includes a picking section. The second conveyor pathway includes a consolidation section. The robotic picking arm is arranged such that items may be picked from a first storage container arranged upon the picking section by use of the robotic picking arm and transferred to a second storage container arranged upon the consolidation section by use of the robotic picking arm. The first conveyor pathway is independently operable of the consolidation section and arranged such that a first storage container may be transferred from a container outlet to a container inlet via the picking section while a second storage container is arranged upon the consolidation section.