Replenishment Control for Storage Containers Using Consumption Feedback

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Solution Overview

Problem

Existing methods for replenishing articles using robots in storage containers are inefficient, leading to either excessive time consumption when individually replenishing or wastage when replacing entire containers.

Innovation Solution

A management apparatus and method that determines whether to individually replenish articles using a picking robot or replace the container based on consumption information, considering factors like consumption amount, variation, and article characteristics to optimize the replenishment process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If articles are individually replenished one by one using a picking robot, then the replenishment can be performed precisely according to consumption, but the time consumption and operational complexity increase significantly

Engineering Contradiction:

Improvewastage of remaining articlesVSAvoidtime consumption for replenishment

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The system changes the parameter of replenishment quantity from individual articles to batch quantities. By determining to replenish a predetermined number of articles at once based on consumption information, the system reduces the number of picking operations while still preventing wastage through intelligent quantity calculation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The management apparatus integrates multiple functions: it monitors consumption information, determines optimal replenishment quantities, and coordinates robot operations. This multi-functional system replaces the need for separate monitoring and replenishment systems, improving efficiency while preventing wastage.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the entire storage container is replaced with a full container, then the replenishment process is simplified and faster, but articles that have not been consumed are wasted

Engineering Contradiction:

Improvereplenishment efficiencyVSAvoidwastage of remaining articles

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The system changes the parameter of replenishment quantity from fixed (entire container replacement) to variable (predetermined number based on consumption). This allows the system to maintain high productivity through batch operations while adapting the quantity to actual consumption needs, thereby preventing wastage.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The management apparatus uses consumption information as feedback to determine the optimal replenishment quantity. By continuously monitoring how many articles have been consumed and calculating the predetermined number to replenish, the system ensures that only necessary articles are added, preventing wastage while maintaining efficient batch replenishment.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If individual article replenishment is performed, then precision in matching consumption is improved, but the operational complexity and cost increase

Engineering Contradiction:

Improveprecision of replenishment quantityVSAvoidcomplexity of replenishment operation

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system changes the parameter of replenishment quantity from individual units to predetermined batches. This reduces the number of discrete operations required while maintaining precision through intelligent calculation of the predetermined number based on consumption information, thereby reducing operational complexity.

Inventive Principle:

Principle #35Parameter changes

4Loss of time

If batch replenishment of predetermined number of articles is performed, then time consumption is reduced, but precision in matching actual consumption needs may decrease

Engineering Contradiction:

Improvetime consumption for replenishmentVSAvoidprecision of replenishment quantity

Core Design Contradiction:

Loss of timeVSMeasurement precision

Solution Approach 1:

The management apparatus uses consumption information as feedback to precisely determine the predetermined number of articles to replenish. This feedback mechanism ensures that batch replenishment maintains high precision by calculating the exact quantity needed based on actual consumption, while still benefiting from the efficiency of batch operations.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12522441B2Management apparatus, management method, and program

Publication Date: 2026.01.13 TOYOTA JIDOSHA KK

AI summary

A management apparatus, a management method, and a program capable of preventing inefficient replenishment from being performed are provided. A management apparatus includes an information acquisition unit configured to acquire consumption information, which is information indicating an amount of consumption of articles stored in a storage container and a replenishment determination unit configured to determine, based on the consumption information, whether to individually replenish articles in the storage container in which the articles have been consumed using a picking robot or to replace the storage container in which the articles have been consumed by a storage container in which a predetermined number of articles are stored.