Unified Container Handling for Conveyor-Free Order Processing
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Solution Overview
Problem
Existing order processing systems, particularly in large installations with high bin retrievals and customer orders, face inefficiencies due to the need for extensive conveyor systems and separate order sortation and handling systems, leading to increased costs and space usage.
Innovation Solution
A unified storage and retrieval system that integrates both storage and delivery containers, using a single type of container for both functions, and employs robotic load handlers to manage these containers within a grid-based system, eliminating the need for separate handling and sortation systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate order sortation and handling systems are used, then order processing can be performed, but equipment investment and floor space requirements increase significantly
Solution Approach 1:
The patent combines the storage system and order sortation system into a single integrated automated storage and retrieval system. The robotic load handlers perform both storage container retrieval and delivery container sortation functions, eliminating the need for separate conveyor systems and sortation equipment, thereby reducing equipment investment and floor space requirements by 70-80%
Solution Approach 2:
The robotic load handlers are designed to perform multiple functions: retrieving storage containers from the automated storage system, delivering them to picking stations, collecting filled delivery containers, and transporting them to dispatch areas. This multi-functional approach replaces dedicated equipment for each function, reducing overall system complexity and space requirements
2Ease of operation
If separate handling systems are used for storage and delivery containers, then container management can be performed, but energy and maintenance costs increase
Solution Approach 1:
The robotic load handlers serve multiple purposes in the container management process, handling both storage containers and delivery containers with the same equipment. This eliminates the need for separate handling systems, reducing energy consumption and maintenance requirements while maintaining full container management capability
3Productivity
If extensive conveyor systems are used for transport and sortation, then large scale order fulfillment can be achieved, but system complexity and costs increase
Solution Approach 1:
The patent merges the functions of conveyor systems and sortation equipment into the automated storage and retrieval system with robotic load handlers. The load handlers directly transport containers between storage, picking stations, and dispatch areas without requiring intermediate conveyor systems, thereby maintaining high productivity while dramatically reducing system complexity
Solution Approach 2:
The patent extracts and eliminates the separate conveyor and sortation system components from the order fulfillment process. By using robotic load handlers that can directly transport and sort containers, the system removes the need for extensive conveyor infrastructure while maintaining the ability to handle tens of thousands of bin retrievals per hour
Data Source
AI summary
Systems, methods, and machine-executable coded instruction sets are disclosed for fully- and/or partly automated handling of goods. The disclosure provides improvements in the storage and retrieval of storage and delivery containers in order processing systems.