Cloud Put-to-Light Pick Cart for Faster Multi-Item Fulfillment
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Solution Overview
Problem
Traditional voice-controlled picking systems in warehouses are inefficient and inaccurate, requiring extensive training and often leading to suboptimal performance in fulfilling orders with multiple items.
Innovation Solution
A cloud-based put-to-light picking system utilizing customized software and specialized hardware, including a pick cart with LED lights and a handheld scanner, that guides users through the most efficient route and quantity of items needed, connected via Wi-Fi for real-time communication and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If voice-controlled picking systems are used, then workers can operate without extensive visual training, but the system becomes inefficient and inaccurate in fulfilling orders with multiple items
Solution Approach 1:
The patent replaces voice-controlled operation with a visual light-based guidance system. Pickers follow illuminated paths and locations rather than relying on voice commands, substituting acoustic control with optical guidance to improve both ease of operation and picking accuracy for multi-item orders
Solution Approach 2:
The system uses different colored lights (e.g., green, yellow, red) to convey different picking instructions and status information. Color-coded guidance indicates pick locations, quantities, and route directions, enabling workers to quickly understand complex picking tasks without extensive training while maintaining high efficiency
2Reliability
If traditional picking schemes are used, then workers can fulfill orders, but the process becomes inefficient and inaccurate when multiple items are in each order
Solution Approach 1:
The system provides real-time feedback through illuminated signals that guide pickers to the correct locations and indicate the required quantities. The light-based feedback system continuously directs workers through the picking process, ensuring accuracy while minimizing time loss by eliminating search and verification steps
Solution Approach 2:
The system pre-calculates and displays the optimal picking route and sequence before the worker begins. By providing the complete picking path and item list in advance through the light guidance system, workers can execute picks systematically without delays for decision-making or route planning
3Productivity
If cloud-based put-to-light system is deployed, then productivity increases by up to 25%, but the device complexity increases with specialized hardware and software
Solution Approach 1:
The patent employs universal components that serve multiple functions: the same light modules provide both directional guidance and location identification, the handheld scanner handles both authentication and product identification, and the cloud platform manages multiple carts and orders simultaneously. This multi-functionality reduces overall system complexity despite the cloud-based architecture
Data Source
AI summary
A picking system may provide a fast, flexible pick cart solution that may be deployed in warehouses or distribution centers to enable users to pick multiple items to put into a plurality of order bins (or carts) with high speed and accuracy to create completed orders ready for packing and shipping. Hardware and software may be bundled on the carts which may shorten training times, simplify integration, and allow for adjustment of carts based on product/items needs, all while improving picking efficiency. The picking system may include a cloud-based computer platform that may control light and displays in the lighted pick shelves that direct users to place a specified quantity of items in specific order bins. Users in remote locations may be linked to the cloud-based computer platform that may control lighted pick shelves in the users' locations.