Vertical Case Sequencing for High-Throughput Order Fulfillment
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Solution Overview
Problem
Current storage and retrieval systems face inefficiencies in sequencing case units during horizontal transfer, leading to slower throughput and reduced productivity in palletizing and packing processes.
Innovation Solution
The implementation of a multi-level transport system with asynchronous level transport systems and independent lift axes that resequence case units vertically, allowing for optimal distribution and ordering of mixed case pallets during the vertical transport process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If case units are sequenced during horizontal transfer, then sequencing is achieved, but throughput is reduced due to slower transfer rates
Solution Approach 1:
The patent transitions sequencing from horizontal transfer to vertical transport by introducing multiple vertically stacked conveyors. Case units are distributed to different vertical levels and then retrieved in sequence from the bottom up, enabling high-speed sequencing without limiting horizontal transfer rates.
Solution Approach 2:
The system divides the sequencing function into separate vertical transport segments. Each vertical conveyor handles a portion of the sequencing task, with case units distributed to different levels and retrieved in a controlled sequence, allowing parallel processing and higher overall throughput.
2Reliability
If sequencing is performed during horizontal transfer, then order fulfillment is achieved, but palletizing speed is reduced
Solution Approach 1:
Case units are pre-positioned on vertical conveyors at different levels before retrieval. The system distributes units to appropriate vertical positions in advance, so that during vertical transport they are automatically retrieved in the correct sequence without delaying palletizing operations.
Solution Approach 2:
The patent moves the sequencing operation from the horizontal plane to the vertical dimension. By stacking conveyors vertically and retrieving units from bottom to top, the system achieves accurate order fulfillment while maintaining high palletizing speeds through parallel vertical transport.
3Productivity
If vertical transport system with multiple conveyors is implemented, then throughput is increased, but system complexity increases
Solution Approach 1:
Each vertical conveyor is designed to perform multiple functions: receiving case units from horizontal conveyors, maintaining units in suspended positions, and retrieving units in sequence. This multi-functionality reduces the need for additional specialized components and simplifies the overall system architecture.
Solution Approach 2:
The patent combines the functions of horizontal transfer and vertical sequencing into an integrated system. Horizontal conveyors feed directly into vertical conveyors, which handle both storage and sequencing functions, eliminating the need for separate buffering and sequencing stations.
Data Source
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AI summary
A product order fulfillment system including a multi-level transport system and a lifting transport system. Each level of the multi-level transport system having a corresponding independent asynchronous level transport system separate and distinct from the asynchronous level transport system corresponding to each other level of the multi-level transport system. Each independent lift axis of the lifting transport system being configured to independently hold at least one case and being communicably coupled to each asynchronous level transport system so as to provide for exchange of the at least one case between each asynchronous level transport system and each independent lift axis. Each independent lift axis is communicably coupled to each other independent lift axis of the more than one lift axis and forms a common output of mixed cases so as to create an ordered sequence of mixed cases in accordance to a predetermined case out ordered sequence.