Multi-Load Shuttle Loading Positions for Drop Sequence Efficiency
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Solution Overview
Problem
Existing order fulfilment systems using shuttles face inefficiencies in coordinating item retrieval, leading to increased cycle time, energy consumption, and the need for manual or automated reshuffling due to improper loading and drop sequencing.
Innovation Solution
A method and apparatus that determine optimal loading positions for a multi-load shuttle based on retrieval and drop sequencing, allowing simultaneous loading without repositioning items, thereby optimizing energy consumption and reducing cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a shuttle loads a first item in a conventional manner, then the item is retrieved and placed on the shuttle, but the loading process blocks subsequent items from being loaded, requiring repositioning operations that increase cycle time and energy consumption
Solution Approach 1:
The system determines optimal loading positions for multiple items before the shuttle begins its retrieval operation. By pre-calculating and pre-positioning items in the correct loading sequence, the system eliminates the need for repositioning operations during the cycle, thereby reducing cycle time and improving loading efficiency
Solution Approach 2:
The system dynamically adjusts loading positions based on the specific configuration of retrieval locations and drop sequencing requirements. By making the loading position determination adaptive to each unique scenario rather than using fixed positions, the system optimizes the loading process to prevent blocking operations
2Ease of operation
If a shuttle retrieves items in the order requests are received, then the retrieval process is simple to coordinate, but drop sequencing requirements cannot be met, necessitating manual or automated reshuffling that increases operational complexity and costs
Solution Approach 1:
The system performs preliminary determination of both loading positions and drop sequencing in advance of the retrieval operation. By calculating the optimal sequence before execution, the system maintains simple coordination during operation while ensuring drop sequencing requirements are met, eliminating the need for reshuffling
Solution Approach 2:
The system uses feedback from the retrieval location data and drop sequencing requirements to dynamically determine the optimal loading sequence. This closed-loop approach allows the system to automatically adjust the retrieval order to match drop requirements without increasing operational complexity
3Adaptability or versatility
If a shuttle repositions items during loading to accommodate subsequent items, then all items can be loaded onto the shuttle, but energy consumption increases due to duplicative repositioning operations
Solution Approach 1:
The system determines the optimal loading positions for all items before the shuttle begins retrieval. By pre-planning the loading sequence based on retrieval locations and drop sequencing, the system eliminates duplicative repositioning operations, thereby reducing energy consumption while maintaining loading flexibility
Data Source
AI summary
Embodiments of the present disclosure provide systems and methods for determining shuttle loading positions for a multi-load shuttle. In one embodiment, a method includes receiving, by one or more processors, an indication of a first load for retrieval by a shuttle that is configurable to simultaneously transport a plurality of loads and an indication of a first retrieval location for the first load; receiving, by the one or more processors, an indication of a second load for retrieval by the shuttle and an indication of a second retrieval location for the second load; determining, by the one or more processors, a first loading position on the shuttle for placing the first load based on the first retrieval location and the second retrieval location; and causing, by the one or more processors, the shuttle to place the first load in the first loading position based on determining the first loading position.