Tote Inclination for Uniform Item Distribution
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Solution Overview
Problem
Existing order fulfillment systems are inefficient in transferring inventory items to empty totes, leading to uneven distribution, underfilling, and potential damage, which slows down the process and reduces efficiency.
Innovation Solution
The system positions empty totes at an angle relative to the horizontal plane, between 5 and 10 degrees, to maximize item transfer and minimize the risk of items falling out, using a conveyor and ramp configuration that directs items into the tote effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If items are transferred horizontally into a tote, then the transfer process is simple, but items are unevenly distributed and the tote is underfilled
Solution Approach 1:
The patent introduces a vertical dimension by inclining the tote at an angle of 5-10 degrees relative to the horizontal plane. This angular adjustment transforms the previously horizontal item transfer into a downward-sloping transfer path, enabling items to slide smoothly into the tote while achieving uniform distribution and maximizing filling efficiency
2Ease of operation
If items are transferred into a horizontal tote, then the transfer mechanism is straightforward, but items may fall out of the tote
Solution Approach 1:
The patent applies asymmetry by positioning the tote at an inclined angle rather than horizontally. This asymmetric orientation creates a natural retention effect where items slide in during transfer but are prevented from falling out, as the opening is elevated relative to the base due to the incline
3Quantity of substance
If the tote is positioned at an angle of 5-10 degrees, then item distribution is maximized and underfilling is prevented, but the system complexity increases
Solution Approach 1:
The patent optimizes the tote inclination angle within a specific range of 5-10 degrees. This parameter optimization ensures that items are effectively channeled into the tote without requiring complex positioning mechanisms, as angles outside this range would either fail to prevent underfilling or would cause items to fall out
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 configuration maximizes the number of items transferred into the tote, reduces the risk of damage, and enhances the overall efficiency of the order fulfillment process by ensuring even distribution and preventing underfilling.
Implementation Method 1
a ramp configured to transfer one or more items from the conveyor to the tote
Data Source
AI summary
An example system includes a conveyor configured to move a plurality of items, a ramp configured to support at least one item of the plurality of items as the at least one item is transferred from the conveyor to a tote, and a platform supported on a support surface and configured to support the tote at a location proximate the ramp. In some examples, the tote includes a base having a top surface defining at least part of an interior space of the tote. Further, the platform positions the tote such that the top surface of the base extends at an angle, relative to a horizontal plane, greater than approximately 5 degrees and less than approximately 10 degrees.