Dual-Bin AGV Sorting for Accurate ASRS Asset Handling

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Solution Overview

Problem

Existing warehouse management systems for mobile phones and tablets are prone to manual errors, inefficiencies, and require significant human intervention, especially in the storage and retrieval of individual assets, leading to increased complexity and inventory discrepancies.

Innovation Solution

An automated guided vehicle (AGV) equipped with a controller, navigation module, cradle unit, and robotic arm, capable of navigating through storage racks, identifying assets, and transferring them between storage bins and racks without manual intervention, using AI and sensor technologies to optimize routing and obstacle avoidance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual sorting and picking is used, then flexibility in handling diverse assets is maintained, but error rate increases and productivity decreases

Engineering Contradiction:
Improveaccuracy of asset identification and storageVSAvoidspeed of picking and sorting operations
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The system enables assets to be automatically identified and sorted through self-service mechanisms. The image sensor and AI module automatically capture and analyze asset images, extract identification codes, and determine storage locations without human intervention. The AGV autonomously navigates to retrieve and deposit assets, creating a self-organizing system that eliminates manual errors while maintaining high throughput.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical sorting operations with an automated vision-based identification system. Instead of workers visually inspecting and manually sorting assets, an image sensor captures images, an AI module processes them to extract identification codes, and this information automatically directs the AGV to the correct storage bin, substituting human cognitive and manual labor with automated optical and computational systems.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Loss of time

If bin-level sorting is implemented, then walking distance for operators is reduced, but human involvement and complexity increase

Engineering Contradiction:
Improvewalking distance and time for operatorsVSAvoidsystem complexity and human intervention requirements
Core Design Contradiction:
Loss of timeVSDevice complexity

Solution Approach 1:

The AGV system performs self-navigation and self-sorting operations without requiring operator intervention. The navigation module autonomously guides the AGV to storage racks and bins, while the image sensor and AI module automatically identify assets and determine their destinations. The system serves itself by making all decisions and executing all actions independently, eliminating the need for operators to walk or manually sort assets.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The AGV acts as an intermediary between the storage racks and the control system, autonomously performing the complex tasks of navigation, asset identification, and physical transport. This intermediary device handles the complexity of coordinated movements and decision-making, freeing operators from involvement while managing the intricate system requirements centrally through the controller.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Productivity

If automated identification and sorting is implemented, then productivity and accuracy improve, but initial system complexity increases

Engineering Contradiction:
Improveefficiency of storage and retrieval operationsVSAvoidcomplexity of automated systems
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The automated system is segmented into distinct functional modules: an image sensor for capturing asset images, an AI module for processing images and extracting identification codes, a controller for decision-making, and a navigation module for physical movement. This segmentation allows each component to perform its specialized function independently, improving overall productivity while managing complexity through modular design that can be implemented and maintained separately.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentEP4663579A1An automated guided vehicle for automated storage and retrieval system
Publication Date: 2025.12.17 GRIFFYN ROBOTECH PVT LTD
  • EP4663579A1 patent drawingFigure 1
  • EP4663579A1 patent drawingFigure 2
  • EP4663579A1 patent drawingFigure 3A~4B

AI summary

An automated guided vehicle, AGV, (100) for moving around in an automated storage and retrieval system, ASRS, (200). The AGV (200) comprising: a first bin holder (40), for receiving a storage bin; a second bin holder (41), for receiving a storage bin; a bin transfer mechanism (42), which is configured to: i) transfer a storage bin between a storage rack and the first bin holder (40); and ii) transfer a storage bin between the first bin holder (40) and the second bin holder (41); and a robot (22) that is configured to: identify assets that are in a storage bin in the first bin holder (40) and identify assets that are in a storage bin in the second bin holder (41); and move assets between a storage bin that is in the first bin holder (40) and a storage bin that is in the second bin holder (41).