AGV Product Picking Control for Lower Search Time and Inventory
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Solution Overview
Problem
Inefficient picking procedures in facilities lead to excessive inventories, wasted time, and increased operational costs due to manual product movement between stations.
Innovation Solution
An autonomous product picking system utilizing automatic guided vehicles (AGVs) that navigate between product pick up and drop off stations, controlled by a system control module that manages call requests and travel times to optimize product movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual product picking is used, then operational flexibility is maintained, but productivity decreases due to increased search time and wasted worker time
Solution Approach 1:
The system enables self-service through automated AGVs that autonomously navigate to pick-up stations, retrieve products, and deliver them to drop-off stations without human intervention. The call stations and system controller work together to automatically dispatch vehicles based on product requests, eliminating the need for manual searching and product movement by operators.
Solution Approach 2:
The patent replaces the manual mechanical system of operators physically moving products with an automated guided vehicle system. The AGVs use sensors, controllers, and navigation systems to autonomously transport products between stations, substituting human physical labor and decision-making with automated mechanical and electronic systems.
2Area of stationary object
If manual product picking is used, then system simplicity is maintained, but floor space utilization deteriorates due to excessive inventories at stations
Solution Approach 1:
The system performs preliminary action by having AGVs proactively pick up products from pick-up stations before they are needed at drop-off stations. The call station system anticipates product needs and dispatches vehicles in advance, allowing stations to maintain lower inventory levels while ensuring product availability when needed.
Solution Approach 2:
The system uses feedback mechanisms where call stations communicate product needs to the system controller, which then dispatches AGVs accordingly. This closed-loop feedback system allows real-time adjustment of inventory levels and product movement, optimizing floor space utilization by moving products based on actual demand rather than maintaining excessive safety stocks.
3Productivity
If manual product picking is used, then operational cost is reduced, but overall cost of operation increases due to wasted time and inefficiency
Solution Approach 1:
The AGV system enables continuous useful action by maintaining constant product movement between stations. Multiple AGVs operate simultaneously on different routes, ensuring that product picking and delivery is an ongoing continuous process rather than intermittent manual operations. This eliminates idle time and keeps the production flow continuous.
Solution Approach 2:
The patent replaces inefficient manual mechanical operations with automated guided vehicles that operate continuously without fatigue, breaks, or delays. The electronic control system optimizes routing and scheduling, replacing wasteful manual processes with efficient automated systems that maximize productive time and minimize operational waste.
Data Source
AI summary
An autonomous product picking system includes product pick up stations at different locations within a facility having call stations with activation buttons at a user interface activated by an operator to transmit call requests when the products are needed to be picked up and to transmit completion signals when the products have been picked up. An automatic guided vehicle is movable within the facility between the product pick up stations and a product drop off station. A system control module guides the AGV within the facility and includes a system communication module communicatively coupled to the AGV and the call stations. The system communication module receives the call requests and the completion signals from the call stations when the activation buttons are activated.