Autonomous Pick-Put Fulfillment With Local AMR Communication
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Solution Overview
Problem
Existing pick-put systems relying on real-time communication with central servers face challenges such as interference, connectivity issues, material interference, and disruptions, leading to inefficiencies and errors, and lack interoperability among multiple AMR systems.
Innovation Solution
An autonomous mobile robot (AMR) system that operates independently with a pick-put controller, using close proximity communication with bay controllers and transceivers to navigate and manage orders without continuous central server connectivity, allowing multiple AMRs to operate cohesively and securely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If real-time communication with central server is used, then order fulfillment efficiency is improved, but system reliability deteriorates due to communication failures and interference
Solution Approach 1:
The system segments communication into two modes: real-time mode for normal operation and asynchronous mode for fault tolerance. Each AMR carries a local copy of the master controller software, enabling independent operation during communication failures. This segmentation allows the system to maintain productivity while improving reliability by not being fully dependent on continuous central server communication.
Solution Approach 2:
The system prepares for communication failures by pre-loading AMRs with local copies of control software and order data before disconnections occur. This beforehand cushioning ensures that when communication interruptions happen, the AMRs can continue operating autonomously without immediate system failure, thus maintaining both efficiency and reliability.
2Adaptability or versatility
If wireless network coverage is expanded to entire floor space, then AMR mobility is improved, but network performance deteriorates due to interference and signal loss
Solution Approach 1:
The system dynamically adapts communication mode based on real-time network conditions. When connectivity is stable, AMRs operate in real-time mode with continuous server communication for optimized performance. When network degradation is detected, the system automatically switches to asynchronous mode, allowing AMRs to maintain operational capability while tolerating reduced network performance, thus preserving mobility without demanding perfect network conditions.
Solution Approach 2:
The local copy of master controller software acts as an intermediary between the AMR and central server. This intermediary enables AMRs to function independently when network conditions are poor, mediating between the need for mobility and the reality of degraded network performance by allowing operations to continue without real-time server communication.
3Reliability
If access points are added to improve coverage, then connectivity is improved, but system complexity increases due to interference and configuration issues
Solution Approach 1:
The system extracts the communication dependency from the AMR-Server relationship by implementing local autonomous control. This extraction reduces the impact of network complexity on system operation, as AMRs can function independently of the centralized communication infrastructure. The complexity of managing multiple access points is mitigated because the system can operate correctly even when communication is intermittent or degraded.
4Measurement precision
If continuous communication with central server is required, then data accuracy is improved, but loss of time increases due to reconnections and delays
Solution Approach 1:
The system performs preliminary actions by pre-loading AMRs with local copies of control software, order data, and navigation routes before communication interruptions occur. This allows AMRs to maintain accurate operation during disconnections without needing to reestablish data streams, eliminating reconnection delays while preserving data accuracy through locally cached information.
Solution Approach 2:
Instead of requiring continuous communication, the system uses periodic synchronization where AMRs update their local data copies from the server at convenient intervals. During interruptions, AMRs continue operating with their current local data. This periodic action reduces time loss by avoiding constant reconnection attempts while maintaining sufficient data accuracy for operational purposes.
Data Source
AI summary
This system can include a pick-put controller in communications with an AMR and using close proximity communications to eliminate the need for facility wide real time transmissions with a central server and facilitate the picking and putting process in facilities that cannot or do not have longer range wireless communications. The pick-put controller can communicate with a bay controller only with close proximity communications. The pick-put controller can transmit instructions to the bay controller which can actuate one or more light indicators. The pick-put controller can direct the AMR to a desired location. The pick-put controller can send instructions to one or more AMR light assemblies. The pick-put controller can record picking and putting events in a storage system which can include a storage database. The AMR can be instructed to travel to a packaging area and upon removal of items picked, return for more order fulfilment.