Robotic Consolidation Station with Independent Conveyors
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Solution Overview
Problem
Existing automated storage and retrieval systems face inefficiencies in the consolidation of multiple items for customer orders, as identical orders are not processed faster than non-identical orders due to sequential access and circulation of storage containers to manual picking/stocking stations, limiting the speed of consolidation processes.
Innovation Solution
A robotic consolidation station with independent conveyor pathways and a robotic picking arm that allows simultaneous transfer and consolidation of storage containers, enabling efficient item picking and transfer between containers within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If storage containers are transferred sequentially through manual picking/stocking stations, then consolidation can be performed, but the processing speed is limited and identical orders are not processed faster than non-identical orders
Solution Approach 1:
The patent replaces the manual picking/stocking station with an automated robotic consolidation station. The robotic system uses automated conveyance and robotic arms to perform consolidation operations, eliminating manual intervention and enabling faster processing speeds for both identical and non-identical orders.
Solution Approach 2:
The patent divides the consolidation process into separate functional zones: a first conveyance system for transporting storage containers to a consolidation zone, and a second conveyance system for transporting consolidated containers. This segmentation allows parallel processing and reduces the time required for sequential circulation.
2Ease of operation
If storage containers are circulated to manual picking stations for consolidation, then items can be consolidated, but the movement distance and system complexity increase
Solution Approach 1:
The patent merges the consolidation operation with the existing storage container circulation system. The robotic consolidation station is integrated into the framework structure, and storage containers are consolidated in-situ during their normal circulation, eliminating the need for separate dedicated consolidation circulation paths.
Solution Approach 2:
The robotic consolidation station acts as an intermediary between the storage container circulation system and the consolidation operation. It receives storage containers from the circulation system, performs consolidation, and returns them to circulation, simplifying the overall system architecture by consolidating functions in a single integrated station.
3Productivity
If identical orders are processed through sequential access to storage containers, then consolidation can be performed, but the processing time is not optimized
Solution Approach 1:
The patent implements preliminary action by pre-positioning storage containers in the consolidation zone before the actual consolidation operation. The first conveyance system transports containers to the consolidation zone in advance, allowing the robotic system to prepare and consolidate items more efficiently without waiting for sequential access.
Solution Approach 2:
The patent ensures continuity of useful action by maintaining continuous operation of the robotic consolidation station. The system can process multiple orders simultaneously and continuously circulate storage containers through the consolidation zone without interruption, optimizing processing speed for both identical and non-identical orders.
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.