Segmented Tote Containers for Multi-Station Warehouse Picking

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Solution Overview

Problem

Inefficient movement of tote containers between picker stations due to varying item types and large order sizes in warehouses, leading to resource waste and increased order fulfillment time.

Innovation Solution

Segmenting parent tote containers into child tote containers based on common item types and picker mechanisms, using robotic picker stations with different retrieval methods, and optimizing the movement of these containers to minimize transfers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If items are scattered across the warehouse and orders include large numbers of items, then order fulfillment can be completed, but the number of tote container movements between picker stations increases

Engineering Contradiction:

Improveorder fulfillment efficiencyVSAvoidtote container movement time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent segments the order fulfillment process by dividing tote containers into different types (first tote containers for first items, second tote containers for second items) and assigns them to different picker stations. This segmentation allows parallel processing of different item types simultaneously, reducing the total time required for order fulfillment and minimizing the number of times tote containers need to be moved between stations.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If different picker mechanisms are used for different item types, then various items can be retrieved effectively, but the complexity of coordinating multiple picker stations increases

Engineering Contradiction:

Improvepicker mechanism compatibilityVSAvoidpicker station coordination complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by assigning specific picker mechanisms to specific picker stations based on the type of items they handle. Each picker station is optimized for its specific function (e.g., suction mechanisms for cans, mechanical fingers for other items), allowing each station to operate independently and efficiently without requiring complex real-time coordination between different mechanism types.

Inventive Principle:

Principle #3Local quality

3Productivity

If tote containers are frequently moved between picker stations, then all items in an order can be collected, but resource waste increases

Engineering Contradiction:

Improveorder completion capabilityVSAvoidresource consumption

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent implements preliminary action by pre-organizing items into different tote container types according to their picker mechanism requirements before the picking process begins. This advance organization ensures that when items need to be retrieved, the appropriate tote containers are already at the correct picker stations, eliminating the need for frequent movements and reducing energy consumption associated with transporting containers between stations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12443922B2System and method for warehouse picking using tote containers

Publication Date: 2025.10.14 WALMART APOLLO LLC

AI summary

A parent tote container is segmented into smaller, child tote containers. Each of the child tote containers includes products that are commonly sold together and are removed from the tote containers at picker stations with the same type of picker mechanism. Items are moved from the child tote containers to a customer order tote container at a picker station.