Temperature-Zoned Tote Handling to Prevent Chilled-Goods Condensation

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Solution Overview

Problem

Automated retail supply chain systems face challenges in maintaining different temperature zones for storing and transporting products, particularly in handling chilled and frozen goods, as existing systems lack efficient temperature control and condensation mitigation for robots and containers.

Innovation Solution

The implementation of an automated order fulfillment system with multiple temperature zones, including ambient, chilled, and frozen areas, utilizing autonomous robotic vehicles and containers designed for different temperature environments, along with a distributed temperature regulation system that uses cooling systems and phase change materials to maintain precise temperature control and prevent condensation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If traditional automated order fulfillment systems store eaches in multi-level storage structures with mobile robots, then automation and productivity are improved, but the ability to maintain different temperature zones and prevent condensation is insufficient

Engineering Contradiction:

Improveautomated order fulfillmentVSAvoidtemperature zone control

Core Design Contradiction:

Extent of automationVSTemperature

Solution Approach 1:

The storage structure is divided into multiple temperature zones (ambient, chilled, frozen) with separate storage locations for each temperature range. Mobile robots are segmented into ambient robots and chilled robots that operate in their respective temperature zones, allowing automated fulfillment while maintaining distinct temperature controls for different product types.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A workstation acts as an intermediary between chilled storage locations and ambient environments. The workstation includes a chilled workspace where chilled eaches can be transferred to ambient eaches containers, mediating the temperature transition and preventing condensation by controlling the transfer environment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If eaches are transferred between containers at different temperatures, then order fulfillment flexibility is improved, but condensation and temperature control problems worsen

Engineering Contradiction:

Improvetemperature transition flexibilityVSAvoidcondensation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

Eaches are pre-cooled in chilled storage locations before being transferred to ambient containers. The workstation maintains a chilled environment during the transfer process, preliminarily preparing the eaches for temperature transition and preventing condensation by avoiding direct exposure to ambient temperature during transfer.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The workstation serves as an intermediary environment that facilitates safe temperature transitions. By maintaining controlled temperature conditions during transfer, the workstation mediates between chilled storage and ambient containers, preventing harmful condensation while enabling flexible order fulfillment.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If mobile robots operate in chilled environments, then chilled product handling capability is improved, but robot complexity and maintenance requirements increase

Engineering Contradiction:

Improvechilled environment operationVSAvoidrobot temperature adaptation

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The robot fleet is segmented into ambient robots that operate in ambient temperature zones and chilled robots that operate in chilled temperature zones. This segmentation allows each robot type to be optimized for its specific environment, improving chilled product handling capability while managing complexity by avoiding the need for all robots to be universally adaptable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different robot designs are used for different temperature zones. Chilled robots are specifically designed with features suitable for chilled environments (such as condensation-resistant components), while ambient robots use standard designs. This local quality approach allows each robot to be optimized for its operating environment without unnecessarily increasing overall system complexity.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables efficient storage and transportation of temperature-sensitive products by ensuring precise temperature control and minimizing condensation, thereby maintaining product freshness and reducing operational costs through modular and efficient temperature management.

Implementation Method 1

a cooling system configured to cool the plurality of containers to the different temperatures

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a liner configured to fit within the enclosure and configured to support the eaches

Methodology Applied

Scientific EffectGravitational force: Gravitation

Data Source

PatentUS11332311B2Tote handling for chilled or frozen goods

Publication Date: 2022.05.17 SYMBOTIC LLC

AI summary

An automated order fulfillment system is disclosed having different temperature zones and robots and containers capable of and/or configured to work in these different temperature zones.