Articulated Arm Robot Picking System for Automated Warehouse Logistics
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Solution Overview
Problem
Existing order-picking systems face inefficiencies due to the need for long-distance transportation of article containers and synchronization challenges without additional buffers or consolidation measures, particularly in high-bay warehouses.
Innovation Solution
An order-picking system featuring a conveyor system that transports storage units between shelves and a manipulator, such as a multi-axis articulated arm robot, to pick articles directly at the interface between the conveyor and transport systems, minimizing the need for long-distance transport of storage units and eliminating the requirement for additional buffers or consolidation measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If items are transported to a static picking station using conveyor systems, then picking can be performed at a centralized location, but transport distances become very long and system complexity increases
Solution Approach 1:
Instead of transporting storage units to a static picking station, the picking station (robotic manipulator) is brought to the storage units. The robotic arm moves along the conveyor system to pick items directly at the storage location, inverting the traditional approach and eliminating long-distance transport of storage units.
Solution Approach 2:
The robotic manipulator serves multiple functions: it can pick items from different storage units at various locations along the conveyor, handle multiple item types, and operate at different picking positions. This multi-functional device replaces multiple dedicated picking stations.
2Productivity
If multiple item containers are transported to a workstation, then all required items can be picked together, but synchronization and buffering requirements increase system complexity
Solution Approach 1:
The robotic manipulator autonomously decides which item to pick next based on the order requirements, without needing external synchronization signals. The system self-regulates by having the robot continuously pick items from different storage units as they pass by on the conveyor, eliminating the need for complex synchronization mechanisms.
Solution Approach 2:
Storage units are prepared in advance and placed on the conveyor system with items accessible for picking. The conveyor system continuously supplies storage units to the robotic manipulator, so items are ready to be picked without waiting for synchronization events or buffering operations.
3Quantity of substance
If storage units are accessed at different vertical positions in high-bay warehouses, then storage capacity is maximized, but vertical transport complexity increases
Solution Approach 1:
The vertical transport function is extracted from the storage system and replaced by a robotic manipulator with vertical movement capability. The robot can reach storage units at different heights directly without requiring complex vertical conveyors, by using its articulated arm to access items at various vertical positions.
Solution Approach 2:
The robotic manipulator acts as an intermediary between the horizontal conveyor system and the vertically stored items. It receives storage units from the horizontal conveyor and can access items at different vertical positions within the storage unit, mediating between the two-dimensional conveyor and three-dimensional storage needs.
Data Source
Figure 1
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AI summary
The present invention relates to a picking system and a method for picking items from storage units (50) of a rack storage system using such a picking system. The picking system comprises a rack storage system with several racks (10, 11, 12, 13, 14), each configured to hold storage units (50), and at least one conveyor system (30) arranged in a rack aisle between the racks (10, 11, 12, 13, 14). Each conveyor system (30) is assigned at least one picking zone, and each conveyor system (30) is configured to transport storage units (50) from an adjacent rack (10, 11, 12, 13, 14) along the rack aisle to the respective picking zone and back. Furthermore, the picking system includes a transport system (40) configured to transport transport units (51) to and from each of the picking zones.