Deep-Row Container Storage Layout for Multi-Bin Robot Picking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing warehousing systems face challenges in achieving high storage density and efficient order picking, as they often rely on inefficient bin-to-person schemes that pick up items one at a time, leading to low storage density and increased operational costs.
Innovation Solution
A warehousing system with inventory frames having multiple levels and storage containers arranged along the depth direction, where robots are controlled to take out adjacent containers simultaneously, optimizing travel paths and reducing the extension length of telescopic components to enhance efficiency and storage density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robots pick up storage containers one at a time using traditional bin-to-person schemes, then the picking process is simple to implement, but the storage density of bins in the warehouse is low and picking efficiency is reduced
Solution Approach 1:
The patent merges multiple storage container pickup operations into a single robotic action. The robot is designed to pick up multiple storage containers simultaneously using a multi-finger gripper mechanism, allowing it to handle several bins in one trip rather than making multiple separate trips for each bin. This combining of operations directly improves picking efficiency while maintaining reasonable system complexity.
Solution Approach 2:
The patent reorganizes the storage layout from traditional single-file bin arrangement to a multi-dimensional configuration where bins are arranged in rows and columns on shelf boards. The robot operates on the floor plane to pick up multiple bins simultaneously, and the loft lifting mechanism adds vertical dimension for transporting bins to different floor operating stations. This dimensional reorganization enables higher storage density and more efficient picking.
2Quantity of substance
If traditional loft-style shelves with single-bin pickup are used, then the system is easy to operate, but the storage density of bins is relatively low
Solution Approach 1:
The patent segments the storage space into multiple shelf boards arranged in rows and columns, with each shelf board containing multiple storage container positions. This segmentation allows the robot to systematically pick up multiple bins in organized groups rather than handling individual bins randomly. The segmented layout optimizes space utilization and enables the robot to service multiple bins per trip, thereby increasing storage density.
Solution Approach 2:
The robotic system is designed with multi-functionality to handle various storage container types and sizes using a universal gripper mechanism. The same robot can pick up multiple different bins simultaneously, and the system can serve multiple operating stations on different floors. This universality allows the system to achieve high storage density without proportionally increasing operational complexity.
3Productivity
If robots make multiple trips to pick up individual bins, then each trip can be optimized for a single task, but the overall picking efficiency is reduced and energy consumption increases
Solution Approach 1:
The patent enables continuous useful action by designing the robot to pick up multiple storage containers in each trip rather than making intermittent trips for single bins. The robot travels to the storage area once and retrieves multiple bins in sequence, maintaining continuous productive action. This eliminates idle return trips and keeps the robot engaged in useful loading operations throughout the cycle, thereby improving picking efficiency and reducing energy consumption per unit of work.
Solution Approach 2:
The system performs preliminary action by pre-organizing storage containers on shelf boards in accessible positions before the robot arrives. The multi-finger gripper is pre-configured to accommodate multiple bin sizes and shapes. This preliminary preparation allows the robot to efficiently pick up multiple bins in a single continuous motion without unnecessary adjustments or repositioning during the picking process, optimizing energy usage and improving overall picking efficiency.
4Adaptability or versatility
If the robot carries mechanism is extended to reach distant bins, then the robot can access more storage locations, but the extension length increases energy consumption and reduces component service life
Solution Approach 1:
The patent applies partial action by designing the robot gripper to extend only as far as necessary to reach the bins on the shelf boards, rather than providing full-length reach to every possible storage location. The multi-finger gripper is positioned to optimally reach the most frequently accessed bins, and less frequently accessed bins are arranged in positions that require minimal extension. This partial extension approach reduces energy consumption and mechanical stress on the extension components while maintaining adequate accessibility to required storage locations.
Data Source
Figure 1
Figure 2A~3B
Figure 4
AI summary
Provided are a container storage system, a warehousing system, a robot control method, and a robot; the container storage system comprises an inventory area (110), a control server (120), a robot (130), and a plurality of workstations (141); the control server (120) communicates with the robot (130) wirelessly; an inventory rack (111) is placed in the inventory area (110); the inventory rack (111) comprises at least one layer of layered panels; the at least one layer of layered panels divides the inventory rack (111) into at least two layers; at least two storage containers are placed on the inventory rack (111) in the direction of the depth of the layered panels, and the direction of width of the storage container on the inventory rack (111) is consistent with the direction of the depth of the layered panels. The technical solution increases the storage density of storage containers in the inventory area, reduces the energy consumption of the robot picking the storage containers, and after a single charge of the robot is complete, the total amount of work that the robot can complete is increased, reducing picking costs.