Multi-Level Bin Retrieval Layout for Faster Warehouse Picking
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Solution Overview
Problem
Existing warehouse systems face inefficiencies in item storage and picking, particularly in response to the expansion of electronic commerce markets, where automated devices struggle to optimize the transportation and retrieval of items for efficient order processing.
Innovation Solution
An automated storage and retrieval system featuring a rack with multiple floors, transportation robots that can lift and transport bins between floors, and picking stations with defined positions for efficient item picking and loading, allowing for improved bin arrangement and reduced physical space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated devices transport trays from rack to order preparation station, then item retrieval is automated, but picking work efficiency remains insufficient due to manual sorting operations
Solution Approach 1:
The system enables operators to perform picking operations directly at the order preparation station without requiring manual transport of trays. The automated device delivers trays autonomously, and operators can immediately process orders using the bin and item holder configuration, making the picking process self-sufficient and eliminating idle time.
Solution Approach 2:
The patent introduces a vertical dimension by implementing multiple levels in the rack structure, allowing trays to be stacked and accessed from different heights. This multi-level arrangement increases storage capacity and enables parallel picking operations at different levels, thereby improving overall picking efficiency.
2Quantity of substance
If multiple bins are stored in the rack, then storage capacity increases, but space utilization deteriorates due to inefficient bin arrangement
Solution Approach 1:
The rack is divided into multiple independent bins, each capable of holding a single item. This segmentation allows for optimized space utilization by arranging bins in a compact grid pattern, maximizing the number of bins that can be stored within the available rack volume while maintaining easy access to individual items.
Solution Approach 2:
The bin is nested within the rack structure, with the item holder positioned inside the bin. This nested arrangement minimizes empty space and ensures that each component serves multiple functions: the rack provides structural support and organization, the bin contains and protects items, and the item holder facilitates easy retrieval.
3Productivity
If bins are arranged in the rack for easy access, then picking speed improves, but storage density decreases due to additional space requirements for bin movement
Solution Approach 1:
The item holder acts as an intermediary component between the bin and the operator. It is positioned at the front of the bin, allowing operators to access items quickly without needing to move the entire bin. This intermediary structure maintains high storage density while enabling fast picking operations.
Solution Approach 2:
The bin is designed with differentiated zones: the front portion contains the item holder for frequent access, while the rear portion provides additional storage space. This local quality differentiation optimizes both picking speed (easy access to frequently ordered items) and storage density (utilization of the entire bin volume).
Data Source
AI summary
There is provided an automated storage and retrieval system including: a rack storing a plurality of bins for containing items; a picking station for picking the item from the bin; and a transportation robot for transporting the bin between the rack and the picking station. The picking station defines one or more picking positions at which the transportation robot transporting the bin is arranged to enable picking work of the item from the bin, and one or more retracted positions at which the transportation robot temporarily retracts the bin from the picking position.