Autonomous Transport Vehicles for Warehouse Order Picking
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Solution Overview
Problem
Current storage and order-picking systems face inefficiencies in sequencing and performance due to the use of steady conveyors in the pre-zone, which require pre-sequencing, occupy significant space, and complicate maintenance, while also limiting flexibility and increasing planning efforts.
Innovation Solution
The system employs a fleet of autonomous driverless transport vehicles (FTF) that operate within a barrier-free FTF plane, coupled with vertical conveyors, allowing for path-optimized retrieval and delivery of goods directly to work stations, eliminating the need for pre-sequencing and enabling flexible assignment of sources to sinks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steady conveyors are used in the pre-zone for transporting articles, then articles can be delivered in a desired order to work stations, but the system requires significant space, complicates maintenance, and increases planning efforts
Solution Approach 1:
The patent replaces the traditional mechanical steady conveyor system with autonomous driverless transport vehicles (FTF) that navigate independently. These vehicles use onboard sensors, navigation systems, and communication protocols to transport articles from storage racks to work stations without requiring fixed conveyor infrastructure, thereby reducing space requirements while maintaining delivery efficiency
Solution Approach 2:
The system transitions from static conveyor paths to dynamic, flexible routing where FTF vehicles can adapt their travel paths in real-time based on traffic conditions, priority levels, and destination requirements. This dynamic approach eliminates the need for extensive fixed conveyor networks while preserving ordered article delivery capability
2Reliability
If steady conveyors with fixed course of lines are used in the pre-zone, then articles can be transported reliably, but the course of lines cannot be changed and maintenance access is difficult
Solution Approach 1:
The patent replaces fixed mechanical conveyor systems with autonomous vehicles that use software-based navigation and routing. This substitution allows the system to maintain reliability through electronic control and communication while dramatically improving maintenance accessibility, as vehicle components can be serviced in standard workshop environments rather than requiring disassembly of fixed conveyor structures
Solution Approach 2:
The FTF vehicles serve multiple functions: they can be reassigned to different routes, adapted to carry different article types, and reconfigured through software updates. This multi-functionality provides system flexibility and reliability without the constraints of fixed conveyor paths, while vehicles can be easily removed and maintained in dedicated service areas
3Productivity
If multiple sequencing stages are used (storage and retrieval devices, elevators, sorting circle), then articles can be delivered in the desired order, but planning and controlling efforts are significant and performance is reduced
Solution Approach 1:
The patent extracts the sequencing function from the traditional multi-stage mechanical system and consolidates it into the autonomous vehicle control system. Each FTF vehicle independently determines its routing and timing based on destination requirements and current system state, eliminating the need for complex coordinated control of multiple sequencing stages while improving overall productivity
Solution Approach 2:
The system introduces a central control system that acts as an intermediary between storage racks and work stations, managing FTF vehicle dispatch, routing, and coordination. This intermediary approach simplifies the overall system by replacing multiple mechanical sequencing stages with a unified digital control layer that optimizes article flow and reduces planning complexity
Data Source
AI summary
A storage and order-picking system and method characterized by a shelf arrangement having shelves, vertical conveyors, and autonomously movable, driverless transport vehicles (FTF) with an FTF plane which is substantially barrier-free and which extends under, over or through the shelf arrangement. The FTF plane is coupled to the shelf arrangement by conveyor technology via the vertical conveyors. The FTF plane has a travel surface with a topology of travel points and segments along which the FTFs move in a guided manner, the segments each extending from one travel point to another adjacent travel point. A fleet manager produces and outputs travel orders for the FTFs, the orders comprising individual navigation information, in order to transport the storage goods, which are not yet transported to the FTF plane by the vertical conveyors in an absolute order, along individual travel paths specifically produced for the FTF away from/to the vertical conveyors.