Circulation Storage Picking for Priority Order Reallocation
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Solution Overview
Problem
Existing systems for processing picking orders with multiple items are inflexible and inefficient, particularly in handling orders of varying priorities and urgent requirements.
Innovation Solution
A system with a central control unit that dynamically assigns picking orders to circulation storage units, using hanging bags for item transport, and employs diverter valves and identification devices to ensure flexible allocation and prioritization of orders, allowing for faster processing of higher-priority items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If items are permanently assigned to orders in fixed storage units, then order fulfillment is straightforward, but the system is inflexible and cannot prioritize urgent orders
Solution Approach 1:
The patent implements dynamic order-item assignment where items are not permanently bound to specific orders but are temporarily assigned based on current priorities. The control system continuously monitors order urgency and reallocates items from circulation storage units to different orders as needed, transforming the static assignment model into a dynamic one that adapts to changing requirements.
Solution Approach 2:
The storage system is divided into multiple independent circulation storage units, each capable of holding various items. This segmentation allows the control system to selectively draw items from different storage units based on order priorities, enabling flexible reconfiguration of item allocations without moving entire storage units or complex structures.
2Speed
If the system processes all orders in sequence, then processing is systematic, but urgent orders cannot be prioritized and delivery time increases
Solution Approach 1:
The control system continuously monitors the status of all orders and the contents of circulation storage units. When an urgent order is detected or when items become available in storage units, the system immediately recalculates priorities and redirects item allocation, creating a feedback loop that ensures urgent orders are processed as quickly as possible without disrupting overall system operation.
Solution Approach 2:
Items are pre-positioned in circulation storage units before being assigned to specific orders. This preliminary placement allows the system to quickly retrieve items for urgent orders without requiring time-consuming searches or transfers from distant storage locations, reducing delivery time while maintaining systematic processing.
3Productivity
If the system uses fixed allocation of items to orders, then resource management is simple, but productivity decreases due to inability to handle priority changes
Solution Approach 1:
The circulation storage units automatically track their own item contents and availability. When items are placed in these units, they are automatically registered in the control system's database. The system then autonomously determines which items to allocate to which orders based on priority levels, eliminating the need for manual resource management while maximizing productivity through intelligent automation.
Data Source
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AI summary
System for processing a large number of picking orders, each with several items, comprising a replenishment warehouse (2) for items, at least one transfer station (3) connected to the replenishment warehouse for transferring items for overhead transport, a buffer storage unit (4) connected to the at least one transfer station comprising a large number of parallel circulation storage units (8) for the overhead transport devices, wherein a switch (11) is arranged at the entrance and at the exit of each circulation storage unit and an item identification device (12) is arranged at the exit of each circulation storage unit, and comprising a central control unit (16) which is configured to assign a large number of picking orders to each circulation storage unit (8) and to create a complete list of all items and their quantity per circulation storage unit (8) from these orders and to supply the items contained therein to the respective circulation storage unit based on the complete list.wherein the suspended transport devices are fed into the respective circulation storage via a switch (11).