Autonomous Mobile Robots for Multi-Level Tote Storage
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Solution Overview
Problem
Conventional order-fulfillment systems in retail supply chains are labor-intensive and lack automation, particularly in each-picking processes, which are inefficient and costly due to manual handling and limited automation.
Innovation Solution
The implementation of a multi-level tote storage structure integrated with autonomous mobile robots and workstations that enable efficient picking, transportation, and placement of items, along with a centralized control system to manage the entire process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual each-picking processes are used in conventional order-fulfillment systems, then operational flexibility is maintained, but labor intensity and costs increase significantly
Solution Approach 1:
The fulfillment system is segmented into autonomous mobile robots for tote transportation and stationary pickers for item selection. This division allows automation of transportation tasks while keeping the picking process relatively simple and adaptable, resolving the contradiction between automation extent and device complexity.
Solution Approach 2:
The autonomous mobile robots are designed with multi-functionality, serving as mobile storage units, transportation carriers, and workstation integrators. This universal design enables high automation without proportionally increasing system complexity, as one component performs multiple functions.
2Productivity
If traditional stationary workstations are used, then picking accuracy is maintained, but order fulfillment speed decreases due to picker movement requirements
Solution Approach 1:
Instead of having pickers move to different totes located elsewhere in the warehouse, the totes are brought to the stationary pickers via autonomous mobile robots. This inversion of the traditional workflow eliminates travel time while maintaining picking accuracy at fixed workstations.
Solution Approach 2:
Autonomous mobile robots serve as intermediaries between the central storage area and the picker workstations. They transport totes to the pickers and return empty totes, enabling fast order fulfillment without requiring pickers to leave their stationary positions.
3Reliability
If multiple totes are stored at each workstation, then product availability increases, but workspace clutter and picking complexity increase
Solution Approach 1:
The system transitions from static tote storage at workstations to dynamic tote delivery via autonomous mobile robots. Totes are brought on-demand to pickers based on order requirements, ensuring product availability without creating permanent clutter or organizational complexity at the workspace.
Data Source
AI summary
An order fulfillment system is disclosed including a multi-level tote storage structure, one or more autonomous mobile robots configured to pick, transport and place one or more tote; one or more workstations configured to accommodate a picker that transports one or more eaches from a tote on one of the autonomous mobile robots to a “put” location, wherein the autonomous mobile robots are configured to move from level to level in the order fulfillment apparatus.