Unified Container Storage Layout for High-Volume Order Fulfillment
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Solution Overview
Problem
Large-scale order processing systems face inefficiencies in handling and storage of containers, leading to extensive conveyor systems and increased costs due to the need for separate order sortation and handling systems, which become impractical with high volumes of bin retrievals and customer orders.
Innovation Solution
Implementing a unified storage and retrieval system that uses a grid or racking configuration to store both storage and delivery containers, allowing robotic load handlers to access all containers without additional cranes or conveyors, and utilizing a single type of container for both storage and delivery that is strong, durable, and lightweight for efficient handling and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate order sortation and handling systems are used for delivery containers, then order fulfillment can be achieved, but device complexity and floor space requirements increase significantly
Solution Approach 1:
The patent merges the storage function and delivery function into a single unified system. The same grid-based storage locations are used to store both inventory containers and delivery containers, eliminating the need for separate sortation systems. This consolidation reduces device complexity while maintaining full order fulfillment capability through robotic load handlers that can retrieve any container type from any location.
Solution Approach 2:
The storage locations in the grid are designed to be universal, capable of holding both storage containers (with inventory) and delivery containers (for order fulfillment). This multi-functionality allows the system to handle both storage and delivery operations through a single infrastructure, reducing the need for dedicated sortation equipment and decreasing overall system complexity.
2Ease of operation
If separate order sortation systems are implemented, then container handling can be performed, but equipment investment and floor space usage increase by 70-80%
Solution Approach 1:
The patent combines container storage and container delivery operations into a single shared infrastructure. The grid-based storage system serves dual purposes: storing inventory and holding delivery containers. This merging eliminates the need for separate sortation equipment and reduces floor space requirements by 70-80% compared to traditional systems with dedicated sortation areas.
Solution Approach 2:
The storage locations are designed as universal receptacles that can accommodate both storage containers filled with inventory and delivery containers prepared for customer orders. This universality allows the same physical space to serve multiple functions, dramatically reducing the floor space needed for container handling operations.
3Adaptability or versatility
If multiple types of containers are used for storage and delivery, then functional requirements are met, but handling efficiency decreases due to incompatibility
Solution Approach 1:
The patent employs a single standardized container design that serves both storage and delivery functions. This universal container type can be used throughout the entire system - for storing inventory, for preparing orders, and for final delivery. The standardized design enables robotic load handlers to handle all containers uniformly, maximizing handling efficiency while maintaining all necessary functional requirements.
4Productivity
If extensive conveyor systems are deployed for high-volume order processing, then throughput capacity increases, but device complexity and energy consumption increase
Solution Approach 1:
The patent extracts and eliminates the conveyor system component from traditional order fulfillment architectures. By using a grid-based storage system with robotic load handlers that can directly retrieve containers from any location, the system removes the need for extensive conveyor networks while maintaining high-volume processing capability through automated robotic operations.
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.