Asynchronous Tote Transfer for Automated Warehouse Order Fulfillment
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Solution Overview
Problem
Current robotic retrieval and delivery systems in warehouses and similar environments are inefficient in fulfilling orders asynchronously, leading to challenges in meeting customer demands and providing timely service as the number of items and orders increases.
Innovation Solution
A fully automated system comprising a first mobile robot for carrying a shelf tote, a second mobile robot for carrying an order tote, a transfer station with a picker having two degrees of freedom, and a control system that coordinates the dispatch and item transfer between the robots, allowing for efficient picking and transfer of items from shelf totes to order totes during movement through the transfer station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional robotic retrieval and delivery systems are used in warehouses, then automation is provided, but efficiency and scalability deteriorate as the number of items and orders increases
Solution Approach 1:
The system segments the order fulfillment process into independent parallel operations: multiple robotic carriers independently retrieve items from different shelves, and multiple pickers simultaneously transfer items to different order totes. This segmentation allows the system to scale horizontally by adding more robots and pickers without increasing coordination complexity, thereby maintaining productivity as automation scales.
Solution Approach 2:
Robotic carriers perform preliminary actions by retrieving items from shelves and bringing them to transfer stations before the actual picking operation. This preliminary positioning of items at transfer stations enables pickers to efficiently transfer items to order totes without traveling throughout the warehouse, significantly reducing the time and complexity of the fulfillment process while maintaining high automation.
2Ease of operation
If synchronous order fulfillment is used, then coordination is simplified, but asynchronous order fulfillment is needed to meet increasing customer demands efficiently
Solution Approach 1:
Transfer stations serve as intermediaries between robotic carriers and pickers, decoupling their operations. Robotic carriers deliver items to transfer stations independently, and pickers retrieve items from transfer stations independently. This intermediary structure enables asynchronous operation where carriers and pickers work at different speeds and schedules without direct coordination, simultaneously improving productivity and maintaining operational simplicity.
3Adaptability or versatility
If manual item picking is used, then flexibility is maintained, but automation and efficiency improve with robotic systems
Solution Approach 1:
The system employs dynamic picker mechanisms that can adapt their movement and picking actions based on the specific items and order requirements. The pickers can adjust their paths, speeds, and picking sequences dynamically, maintaining flexibility similar to manual operations while achieving the speed and consistency of automation. This dynamic adaptability allows the system to handle varied order configurations efficiently.
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for fully automated order fulfillment. A method includes identifying a shelf tote having an item contained therein for transfer to an order tote; dispatching a first carrier to pick up the shelf tote and a second carrier to pick an order tote; causing the picker to pick the item from the shelf tote while the shelf tote is moving through the transfer station; and transferring the item to the order tote by the picker.