Automated Loading and Unloading Stations for Intermediate Storage Devices
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Solution Overview
Problem
In order-picking systems, the manual loading and unloading of intermediate storage devices by pickers leads to increased travel time and reduced efficiency, especially in multi-stage or multi-zone picking scenarios, where pickers often hinder each other during unloading and loading processes.
Innovation Solution
Mechanizing the loading and unloading of intermediate storage devices at designated stations, with the introduction of a storage/sorting area that acts as an intermediate store for collected items, and using an intermediate conveyor to transport these devices between loading and unloading stations, allowing for separation into storage and moving parts for easier handling and reduced picker workload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and unloading of intermediate storage devices is performed by pickers, then flexibility and simplicity are maintained, but travel time increases and efficiency decreases
Solution Approach 1:
The loading and unloading station performs automated loading and unloading operations without requiring picker intervention. The system serves itself by mechanically loading collection means onto intermediate storage devices and unloading them at designated stations, eliminating the time pickers would spend on these non-value-added tasks.
Solution Approach 2:
The picking system is divided into distinct functional zones: picking areas where pickers work, and separate loading/unloading stations where automated operations occur. This segmentation allows pickers to focus solely on picking while automated systems handle loading and unloading, reducing travel time and improving overall productivity.
2Productivity
If multiple pickers work in the same base area for loading and unloading, then resource utilization is improved, but mutual interference increases and picking time extends
Solution Approach 1:
Multiple loading and unloading stations are distributed across different picking zones rather than concentrating all operations in a single base area. This spatial segmentation eliminates mutual interference between pickers while maintaining high resource utilization, as each picker operates independently in their assigned zone.
Solution Approach 2:
The system transitions from a centralized two-dimensional base area to a distributed three-dimensional arrangement of multiple stations across different picking zones. This dimensional change allows parallel operations without interference, improving both productivity and operational smoothness.
3Productivity
If intermediate storage devices are manually handled by pickers, then device complexity is minimized, but picker workload increases and efficiency decreases
Solution Approach 1:
Intermediate storage devices are equipped with mechanical loading and unloading capabilities that operate automatically at designated stations. The devices serve themselves by being mechanically loaded with collection means and unloaded without picker intervention, reducing picker workload while increasing picking speed.
Solution Approach 2:
Automated loading and unloading stations act as intermediaries between the storage system and pickers. These intermediary devices handle the complex mechanical operations of loading and unloading intermediate storage devices, isolating the complexity from pickers while enabling faster picking operations.
Data Source
Figure 1~3
AI summary
The method involves manually collecting articles from commissioners into collecting units e.g. cardboard boxes. The collecting units are carried along from the commissioners into intermediate storage devices during commissioning process. One of the intermediate storage devices is automatically loaded with the collecting units in loading- and unloading stations (6) and/or one of the collecting units is automatically unloaded from the intermediate storage devices into the loading-and unloading stations. An independent claim is also included for an arrangement for commissioning an article in a commissioning system.