Dynamic pick wall/put wall
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Solution Overview
Problem
In distribution centers, order picking systems face inefficiencies due to the need for frequent adjustments and reconfigurations of pick/put walls to accommodate different item sizes, which decreases throughput and increases downtime.
Innovation Solution
A dynamic storage wall system equipped with a sensor array and a workflow control system that automatically measures and adjusts the positions of repositionable dividers and recognizes operator gestures, reducing the need for manual adjustments and providing real-time visual cues for accurate picking and placing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of storage wall components is performed to accommodate different item sizes, then adaptability is improved, but productivity deteriorates due to increased downtime and reconfiguration time
Solution Approach 1:
The storage wall system transitions from static to dynamic configuration through automated sensor detection and electronic indicator repositioning. The system automatically adapts to different item sizes and storage location configurations without requiring manual physical adjustment of components, thereby maintaining productivity while achieving adaptability.
Solution Approach 2:
The storage wall system performs self-reconfiguration through integrated sensors that automatically detect item placement and trigger corresponding changes in electronic indicators. The system serves itself by eliminating the need for operator intervention in the reconfiguration process, thus preventing productivity loss while maintaining adaptability.
2Measurement precision
If manual measurement and positioning of indicators is performed to ensure accuracy, then measurement precision is improved, but productivity deteriorates due to increased time for manual adjustment
Solution Approach 1:
The system replaces manual mechanical measurement and positioning with automated optical sensors and electronic indicator control. Sensors automatically detect storage location boundaries and item positions, eliminating the need for manual measurements while maintaining high precision through electronic positioning of pick-to-lights and displays.
Solution Approach 2:
The system implements continuous feedback through sensors that monitor storage location configurations and item positions. This feedback loop enables automatic adjustment of electronic indicators to match actual physical conditions, ensuring measurement precision without manual intervention and preventing productivity deterioration.
3Ease of operation
If photocell sensors are used to sense item movement, then ease of operation is improved, but reliability deteriorates in poor lighting conditions
Solution Approach 1:
The system changes the operating parameter of sensors from optical (photocell) to alternative detection methods that are not affected by lighting conditions. This may include using sensors that detect item presence through other physical properties, ensuring reliable operation across all lighting environments while maintaining ease of use.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system enhances throughput by minimizing downtime and operational inefficiencies, allowing operators to focus on picking and placing tasks without manual reconfiguration of storage walls, and operates reliably in various lighting conditions.
Implementation Method 1
The sensor array includes a time of flight (ToF) sensor to measure a distance from a known location to each of the repositionable dividers to measure the position of each of the repositionable dividers
Data Source
AI summary
A dynamic storage wall with reconfigurable storage cubbies and methods of operating the storage wall are provided for a storage facility. The storage wall includes a shelf with multiple storage cubbies and one or more repositionable dividers defining boundaries between the cubbies. The storage wall includes a Time of Flight (ToF) sensor array adjacent to the shelf for measuring positions of each of the repositionable dividers. The ToF is also adapted for recognizing when an item has been retrieved from or placed at either of said storage locations. A workflow control system with a computer is connected to the sensor array. The control system utilizes data from the ToF sensor array to determine when a repositionable divider has been moved and/or when an item has been retrieved from a storage location. The system may automatically or manually recognize when a divider is moved and that new measurement is required.