Stackable Tote Rim Relief for Stable Robotic Pallet Stacking
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Solution Overview
Problem
The stacking of open-topped or unlidded totes in automated storage and retrieval systems often results in unstable stacks and potential damage to contents due to the superior totes falling into inferior totes.
Innovation Solution
The implementation of breakpack goods containers with a frustum-shaped tote casement featuring a relief channel and a flat surface, which allows for secure nesting and stacking without dropping, using a robot's end of arm tool to guide the stacking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If open-topped or unlidded totes are stacked one on top of another using conventional palletizing automation, then stacking efficiency and automation are improved, but stack stability deteriorates and contents may be damaged due to superior totes falling into inferior totes
Solution Approach 1:
The tote design enables superior totes to nest within inferior totes during stacking, with the upper tote's bottom surface inserting into the lower tote's interior space. This nesting arrangement prevents the superior tote from falling into the inferior tote while maintaining stable stacking, allowing automated palletizing to proceed efficiently without compromising stack reliability
2Ease of manufacture
If conventional flat-bottomed containers are used for stacking, then manufacturing simplicity is maintained, but stacking stability deteriorates due to lack of engagement features
Solution Approach 1:
The container bottom is designed with localized structural features including a front wall, rear wall, and side walls that create an engagement geometry. These local structural modifications enable the bottom surface to engage with the superior container's lower opening, providing stacking stability while maintaining overall manufacturing simplicity through the integrated frustum design
Data Source
AI summary
A stackable tote for an automated storage and retrieval system. The stackable tote includes a tote casement of a general frustum shape with walls forming a void within the tote casement. A top of the tote casement surrounding the void has an upper rim, bounding an opening of the void, the upper rim having a flat surface for contacting and supporting another tote received by automation. A relief channel is formed in the upper rim forming an escapement space for an end of arm tool of a robot automatically stacking the other tote with the stackable tote to form a stack with a standard height on a standard pallet.