Autonomous Mobile Robots for Fulfillment Center Sorting

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Solution Overview

Problem

Current robotic sorting systems in fulfillment centers are costly to install, require extensive infrastructure, and pose safety risks to employees, while also being inefficient due to the need for continuous human intervention and complex machinery.

Innovation Solution

The implementation of mobile robots that can be manually loaded with items and coordinated by a remote computer system or autonomously to transport and sort items between locations, reducing the need for extensive infrastructure and allowing human workers to safely operate alongside the robots.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a robotic sorting system with picking machine and conveyors is implemented, then item gathering and moving efficiency is improved, but startup capital cost and infrastructure requirements increase significantly

Engineering Contradiction:

Improveitem gathering and moving efficiencyVSAvoidinfrastructure requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the fulfillment center into multiple zones with multiple autonomous mobile robots operating independently. Each robot is a self-contained unit that performs picking, sorting, and transporting functions, eliminating the need for centralized complex infrastructure like conveyor systems and large picking machines.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Mobile robots are equipped with autonomous navigation capabilities, onboard processors, and sensors that allow them to independently determine their locations, plan routes, avoid obstacles, and coordinate with other robots without requiring extensive external control infrastructure.

Inventive Principle:

Principle #25Self-service

2Productivity

If a robotic sorting system with picking machine is implemented, then item processing speed is improved, but system reliability decreases due to single points of failure

Engineering Contradiction:

Improveitem processing speedVSAvoidsystem continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system uses multiple independent mobile robots instead of a single centralized picking machine. Each robot operates autonomously, so if one robot fails, others continue to function, eliminating single points of failure and ensuring system continuity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from centralized mechanical conveyors to distributed autonomous mobile robots, changing the operational parameters from fixed infrastructure to flexible autonomous units that can adapt and continue operation despite individual failures.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If a robotic sorting system operates in aisle ways, then item gathering efficiency is improved, but employee safety is compromised

Engineering Contradiction:

Improveitem gathering efficiencyVSAvoidemployee injury risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Mobile robots autonomously navigate aisle ways using onboard sensors and processors to detect employees and obstacles, dynamically adjusting their paths to avoid collisions. This autonomous safety monitoring allows robots to operate safely alongside employees without requiring aisle restrictions.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system transitions from static conveyor infrastructure to dynamic mobile robots that can adapt their movement and positioning in real-time based on employee presence, maintaining productivity while ensuring employee safety through flexible, responsive navigation.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If manual item loading onto mobile robots is implemented, then device complexity is reduced, but labor requirements increase

Engineering Contradiction:

Improverobot system complexityVSAvoidhuman labor input

Core Design Contradiction:

Device complexityVSQuantity of substance

Solution Approach 1:

The system uses manual loading only for the initial placement of items onto robots, while automated processes handle the majority of operations including navigation, sorting, and delivery. This partial automation approach reduces overall system complexity while maintaining efficiency.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

Mobile robots serve as intermediaries between storage locations and destinations, accepting items from employees and autonomously transporting them. This intermediary role reduces the need for employees to perform repetitive picking and transporting tasks while keeping the robot design relatively simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9463927B1Transporting and/or sorting items with mobile robot(s)

Publication Date: 2016.10.11 VECNA ROBOTICS INC

AI summary

Mobile robots and methods involving mobile robots are provided. In one method, one or more items are manually loaded with one or more mobile robots. Operation of the mobile robots is coordinated, by a remote computer system and/or by one or more of the mobile robots, to sort and transport the items. The coordinated operation includes autonomously moving the mobile robots within their operating environment between respective locations.