Pallet Transport Layout Using AGVs for Faster Layer Picking
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Solution Overview
Problem
Conventional pallet transportation systems, such as conveyor belt systems and forklifts, are inefficient and costly due to their fixed paths and reliance on manual operation, limiting flexibility and increasing operational costs in warehouse environments.
Innovation Solution
The implementation of automated guided vehicles (AGVs) and algorithms that optimize pallet movement and arrangement within a gridded assembly area, allowing for dynamic path generation and efficient relocation of layers between pallets, thereby reducing travel distance and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional conveyor belt systems and forklifts are used for pallet transportation, then pallets can be moved between locations, but the system lacks flexibility and requires fixed paths and manual operation
Solution Approach 1:
The patent implements dynamic, reconfigurable pallet transportation paths using automated guided vehicles (AGVs) that can adapt their routes in real-time based on warehouse conditions, eliminating fixed conveyor belt paths while maintaining transportation capability through software-controlled navigation
Solution Approach 2:
The patent replaces mechanical conveyor belt systems with automated guided vehicles that use sensors, algorithms, and intelligent navigation to achieve pallet transportation, substituting rigid mechanical infrastructure with flexible software-controlled mobile robots
2Productivity
If manual operation of forklifts is used for pallet transportation, then pallets can be relocated, but operational costs increase and efficiency decreases
Solution Approach 1:
The patent implements self-service automation where automated guided vehicles independently navigate, transport pallets, and return to assembly areas without human intervention, using onboard sensors and algorithms to make autonomous decisions about path selection and pallet handling
Solution Approach 2:
The patent incorporates feedback mechanisms where the central controller receives real-time data from automated guided vehicles about pallet locations, vehicle positions, and assembly area status, then dynamically adjusts routing and task allocation to optimize operational efficiency
3Loss of time
If pallets are arranged without optimized zoning, then assembly area can accommodate all pallets, but travel distance and time for layer picking increase
Solution Approach 1:
The patent applies local quality optimization by dividing the assembly area into zones based on pallet velocity characteristics, placing fast-moving pallets in accessible locations near the layer picker and slow-moving pallets in less accessible areas, thereby minimizing travel time for frequently accessed pallets
Data Source
AI summary
A layer pick system optimizes usage of a layer picker gantry or robotic arm by arranging and/or displacing the gantry or arm in optimal locations with respect to one or more groups of pallets, and/or by grouping pallets by their attributes and arranging the same group of pallets close to each other. In some implementations, a plurality of pallets is categorized into multiple groups by different velocities.