Modular Actuated Rotary Put-Wall for Robotic Order Consolidation
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Solution Overview
Problem
Existing material handling systems in distribution centers face inefficiencies in order consolidation due to complex workflows and limited automation in put-wall systems.
Innovation Solution
A modular actuated rotary put-wall system that utilizes a plurality of totes and internal vertical reciprocating conveyors to efficiently consolidate items for customer orders, with robotic devices for item handling and transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional put-wall systems are used for order consolidation, then items can be consolidated in a common repository, but the operational cycle time is long and efficiency is limited
Solution Approach 1:
The put-wall system is transformed from a static structure to a dynamic rotary carousel that rotates to bring different cubbies to the deposit position. This dynamic configuration allows continuous operation without idle time, as the carousel can be rotated to position the next required cubby at the deposit point, thereby reducing operational cycle time and improving order consolidation efficiency
Solution Approach 2:
Items are pre-positioned in totes on the conveyor before reaching the put-wall. The robotic device picks items from these pre-positioned totes and places them directly into the appropriate cubbies on the rotary carousel. This preliminary organization of items enables faster consolidation without requiring additional search or handling time during the order fulfillment process
2Productivity
If manual item handling is used in put-wall systems, then flexibility is maintained, but automation extent is low and productivity is reduced
Solution Approach 1:
The robotic device autonomously picks items from totes on the conveyor and places them into the appropriate cubbies on the rotary carousel without human intervention. The system self-regulates by receiving signals from the control system about which items need to be consolidated and automatically performs the sorting and depositing actions, thereby increasing both productivity and automation extent
Solution Approach 2:
The control system receives information about customer orders and item locations, then directs the robotic device to pick specific items and place them in the correct cubbies. The rotary carousel position is also monitored and controlled to ensure the correct cubby is at the deposit position. This feedback loop enables precise automated control while maintaining flexibility to handle varying order requirements
3Adaptability or versatility
If complex workflows are used for order consolidation, then comprehensive sorting is achieved, but device complexity increases
Solution Approach 1:
The put-wall system is divided into multiple independent cubbies arranged on a rotary carousel, with each cubby capable of being independently positioned at the deposit location. This segmentation allows the system to handle multiple different order configurations simultaneously while maintaining a relatively simple overall structure, as each cubby operates independently rather than requiring complex mechanical sorting mechanisms
Solution Approach 2:
The rotary carousel serves multiple functions: it stores items in cubbies, rotates to position different cubbies at the deposit point, and enables continuous operation by bringing the next required cubby into position. This multi-functionality reduces the need for separate dedicated mechanisms for each sorting task, thereby decreasing overall device complexity while maintaining high adaptability for various order consolidation scenarios
Data Source
AI summary
Various embodiments illustrated herein disclose an apparatus. The apparatus comprises a rotary put wall having a plurality of totes. The apparatus further comprises a vertical reciprocating conveyor (VRC) placed within the rotary put wall. The internal vertical reciprocating conveyor (VRC) comprises a plurality of chutes to receive one or more items from a robotic device. The internal vertical reciprocating conveyor (VRC) is further configured to be rotatable with respect to the rotary put wall and to convey the one or more items into one tote of the plurality of totes of the rotary put wall.