Autonomous Order Picking and Packing With Ergonomic Box Handling
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Solution Overview
Problem
Existing logistics systems in warehouses face inefficiencies due to complex and inflexible order preparation methods, ergonomic challenges, and difficulties in managing mobile robots, leading to increased operational time and health risks for order pickers/packers.
Innovation Solution
A method and system utilizing self-guiding vehicles to transport storage containers and cardboard boxes to an ergonomic order preparation station with adjustable parking spaces, allowing flexible order preparation and packing, reducing ergonomic strain and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyors or robots on travel rails are used to transport products to the order preparation station, then productivity is improved, but device complexity increases and warehouse space requirements increase
Solution Approach 1:
The patent replaces complex mechanical conveyor systems and rail-based robot guidance with autonomous mobile robots that navigate autonomously using sensors and navigation algorithms. This substitution reduces mechanical infrastructure complexity while maintaining automated transport functionality, directly resolving the contradiction between improved productivity and reduced device complexity
Solution Approach 2:
The mobile robots are equipped with autonomous navigation capabilities, allowing them to self-guided to the order preparation station without requiring external mechanical guidance infrastructure. The robots independently determine their own paths and execute transport tasks, eliminating the need for complex conveyors or rail systems while achieving automated order preparation
2Productivity
If conveyors or rail-based robots are used, then order preparation speed is improved, but adaptability deteriorates as the order sequence cannot be changed once loading begins
Solution Approach 1:
The system dynamically adjusts the order sequence of robot arrivals at the preparation station based on real-time order priorities. The centralized control system can reassign tasks and modify arrival sequences mid-process, allowing flexible adaptation to changing order requirements while maintaining continuous automated operation and high productivity
Solution Approach 2:
The centralized control system continuously monitors order priorities and robot positions, using this feedback information to dynamically adjust task assignments and arrival sequences. This closed-loop control enables the system to adapt to changing order requirements in real-time while maintaining efficient automated operation
3Adaptability or versatility
If mobile robots are used for order preparation, then adaptability is improved, but ergonomic problems arise due to awkward transfer operations
Solution Approach 1:
The system positions the mobile robot and the collection container at the same height level during product transfer operations. This height alignment eliminates the need for awkward lifting or reaching movements by the operator, creating an ergonomic workspace where products can be transferred smoothly between the robot and container without musculoskeletal strain
Data Source
AI summary
A method for order preparation and packing includes bringing at least one storage container for at least one item, by means of at least one vehicle of a first set of self-guiding vehicles adapted to travel across the floor, to an order preparation station; selecting a first cardboard box intended to form the packaging of a parcel for one of the orders; bringing the first cardboard box selected, by means of at least one vehicle of a second set of self-guiding vehicles adapted to travel across the floor, to the order preparation station; and taking at least one item from one of the storage containers and placing the item(s) taken in the first cardboard box selected.