Robotic Grid Container Handling for Unified Order Fulfillment
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Solution Overview
Problem
Current automated order fulfillment systems face inefficiencies in handling and storage of containers, particularly in large-scale operations, leading to increased costs and space requirements due to the need for extensive conveyor systems and separate handling systems for storage and delivery containers.
Innovation Solution
Implementing a unified storage and retrieval system that uses a grid or racking arrangement for both storage and delivery containers, with robotic load handlers accessing all containers within the system, and employing a single type of container for both storage and delivery, which is strong enough for handling and transportation but light enough for efficient delivery, and featuring structural features like holes for easy automated removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate order sortation and handling systems are used for storage and delivery containers, then container handling can be performed with simple individual container designs, but extensive conveyor systems and separate handling systems are required leading to increased equipment investment and floor space requirements
Solution Approach 1:
The patent merges the functions of storage container handling and delivery container handling into a single unified storage and retrieval system. Both container types are stored and retrieved using the same robotic load handlers and grid infrastructure, eliminating the need for separate conveyor systems and handling mechanisms for each container type.
Solution Approach 2:
The unified storage and retrieval system performs multiple functions: it stores both storage containers and delivery containers, retrieves both types, and manages both types using the same robotic load handlers. This multi-functional approach replaces multiple specialized systems with a single versatile system.
2Adaptability or versatility
If separate handling systems are used for storage and delivery containers, then each container type can be optimized for its specific function, but equipment investment and energy costs increase significantly
Solution Approach 1:
The system combines storage and delivery container handling into a single infrastructure, reducing the total number of handling systems required. This consolidation decreases energy consumption by eliminating redundant motors, conveyors, and control systems while maintaining the ability to handle both container types effectively.
3Ease of operation
If separate handling systems are used for storage and delivery containers, then specialized handling mechanisms can be designed for each container type, but floor space requirements increase due to extensive conveyor systems
Solution Approach 1:
The patent consolidates storage and delivery container handling into a single vertical grid system with robotic load handlers that operate in three-dimensional space. This eliminates the need for extensive horizontal conveyor systems, significantly reducing floor space requirements while maintaining specialized handling capabilities through programmable robotic operations.
Solution Approach 2:
The system transitions from two-dimensional horizontal conveyor-based handling to three-dimensional vertical stacking and robotic retrieval. Containers are stacked vertically in the grid system, and robotic load handlers move along vertical and horizontal rails to access containers at any level, maximizing space utilization and minimizing floor space requirements.
4Use of energy by stationary object
If a unified storage and retrieval system is used for both storage and delivery containers, then equipment investment and energy costs are reduced by 70-80%, but both container types must share the same handling infrastructure
Solution Approach 1:
The robotic load handlers are designed with universal end-effectors and control systems that can accommodate both storage containers and delivery containers. The system maintains flexibility through programmable operations that adapt to different container types, sizes, and handling requirements while using the same physical infrastructure.
Data Source
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AI summary
Systems 1000, methods, and machine-executable coded instruction sets for the fully- and/or partly automated handling of goods. In particular, the disclosure provides improvements in the storage and retrieval of storage and delivery containers in order processing systems. In embodiments, a frame defines a grid of storage locations configured for storing a plurality of storage containers in rows and columns of stacks 30 of storage containers, and there are a plurality of overhead robotic load handlers 40 for transporting storage containers to and from storage locations within the grid, and a plurality of delivery containers, each being configured for storage in the grid as a combined container 90 which comprises one or more delivery containers 10, 80 stored within a storage container 10, 70.