Vertical Article Storage And Order Sortation For Compact Fulfillment
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Solution Overview
Problem
The challenge of fitting all order fulfillment automation equipment within a limited footprint, particularly when expanding the footprint is expensive or impracticable, is addressed by optimizing available space capacity in a cost-effective manner.
Innovation Solution
A system comprising an order sortation system with computer-controlled vehicles and an article storage and retrieval system positioned above it, allowing for efficient retrieval and sorting of articles into destination receptacles, with a controller managing the process to optimize space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If automated storage and retrieval system and order sortation system are positioned separately, then each system can operate independently, but the footprint space required increases
Solution Approach 1:
The patent combines the automated storage and retrieval system with the order sortation system into a single integrated structure. The storage system is positioned directly above the sortation system, allowing both systems to occupy the same footprint space while maintaining independent operational capabilities through shared infrastructure components.
Solution Approach 2:
The patent transitions from a horizontal layout where systems are positioned side-by-side to a vertical layout where the storage system is stacked above the sortation system. This dimensional change allows both systems to coexist within the same footprint by utilizing the vertical space, effectively reducing the ground area required.
2Quantity of substance
If footprint expansion is allowed, then more equipment can be accommodated, but cost increases significantly
Solution Approach 1:
The patent implements a nested configuration where the order sortation system is positioned within the vertical projection of the automated storage and retrieval system. This nesting allows both systems to be accommodated within the same footprint, maximizing equipment capacity without requiring additional space expansion, thereby maintaining cost-effectiveness.
3Productivity
If manual order fulfillment is used, then equipment cost is reduced, but productivity and efficiency decrease
Solution Approach 1:
The integrated system performs multiple functions within a single footprint: the automated storage and retrieval system handles article storage and retrieval, while the order sortation system handles order assembly and sorting. This multi-functionality increases productivity without requiring separate dedicated spaces for each function, making the automation investment more justifiable.
Data Source
AI summary
Order fulfillment system comprises an order sortation system and an article storage and retrieval system positioned directly above the order sortation system. A controller is configured to: receive an order; direct a retrieval mechanism to move a storage bin containing a first article required for the order to an output station; determine a first destination receptacle among a plurality of destination receptacles to deliver, with a computer controlled vehicle, the first article based on a destination determined for the first article; direct collecting, at the output station, of the first article from the storage bin; direct the computer controlled vehicle to transport the first article received at the output station to the first receptacle.