Dynamic Storage Picking System with AGV Manipulators
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Solution Overview
Problem
Current storage and picking systems operating on the man-to-goods principle face inefficiencies such as long distances traveled by order pickers, low picking performance, suboptimal workload distribution, and the need for expensive sorting devices, especially in e-commerce applications with unique order structures.
Innovation Solution
Implementing a dynamic storage and picking system where AGVs handle destinations dynamically and sources dynamically, allowing manipulators to select transfer locations in real-time, enabling parallel processing of orders and optimized workload distribution without the need for a separate sorting device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If order pickers manually retrieve goods from static shelves and move through the warehouse, then the system structure is simple, but the pickers have to cover long distances and picking performance is low
Solution Approach 1:
The patent inverts the traditional man-to-goods principle by implementing goods-to-man autonomous vehicles that autonomously navigate to pickers and transfer goods. Instead of pickers moving through the warehouse to collect items, autonomous vehicles bring goods to designated pickers, fundamentally reversing the flow direction and eliminating long travel distances for human operators.
Solution Approach 2:
Autonomous vehicles are equipped with navigation systems and automated goods handling capabilities, enabling them to independently locate pickers, navigate to storage locations, retrieve goods, and deliver them without human intervention. The vehicles perform the entire transport task autonomously, freeing pickers from movement requirements and dramatically improving picking efficiency.
2Extent of automation
If autonomous vehicles are used to transport goods with single-stage order picking, then the system is more automated, but the vehicles have to cover long distances and process orders slowly
Solution Approach 1:
The patent segments the order fulfillment process into multiple stages: autonomous vehicles transport goods to consolidation racks where items are sorted and consolidated by destination, then transferred to delivery vehicles. This segmentation allows parallel processing of multiple orders simultaneously, as different vehicles can service different racks and destinations at the same time, dramatically increasing overall order processing throughput.
Solution Approach 2:
Consolidation racks serve as intermediary structures between storage areas and delivery points. Vehicles deposit goods at consolidation racks rather than delivering directly to final destinations, allowing multiple vehicles to contribute items to the same order concurrently. This intermediary step enables efficient parallel assembly of orders from multiple sources without requiring vehicles to traverse the entire warehouse for each item.
3Ease of operation
If a separate sorting system is implemented for two-stage order picking, then goods can be distributed according to orders, but the sorting system is expensive and requires additional control and monitoring
Solution Approach 1:
Autonomous vehicles serve multiple functions: they transport goods from storage to consolidation racks, deliver consolidated orders to destinations, and can dynamically adjust their routes based on real-time order requirements. This multi-functionality eliminates the need for dedicated sorting equipment, as the vehicles themselves perform the sorting and delivery functions through intelligent routing and consolidation operations.
Solution Approach 2:
The system employs dynamic route planning and real-time optimization where vehicle destinations and routes are continuously adjusted based on current order priorities and consolidation needs. Rather than using fixed sorting infrastructure, the system dynamically assigns vehicles to different consolidation racks and destinations, allowing flexible adaptation to varying order patterns without additional hardware complexity.
4Productivity
If zone picking is implemented with conveyor systems, then goods can be sorted by zone, but order pickers are not optimally utilized and personnel costs increase during peak times
Solution Approach 1:
Autonomous vehicles autonomously perform the function of conveyor systems by navigating to consolidation racks, picking up goods, and delivering them to appropriate destinations. This self-service capability eliminates the need for complex mechanical conveyor infrastructure while maintaining the ability to sort and distribute goods by zone, significantly reducing device complexity and associated maintenance costs.
Data Source
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AI summary
The invention discloses a method (70) for operating a storage and picking system (10), in which a multiplicity of manipulators (40) processes a multiplicity of picking/storage orders in accordance with a manipulator-to-handling-unit principle, wherein the system (10) has a supply zone (12), a picking zone (14), a multiplicity of supply units (42, 62) in the supply zone, a multiplicity of in particular statically arranged transfer positions (46) in the picking zone (14), an FTS (18) with a multiplicity of FTF (20), and a controller (32), and wherein the method (70) has the following steps: analysing (S10) the multiplicity of picking/storage orders by way of the controller (32) for the purposes of determining removal/setting-down locations in the supply zone (12); defining (S12) transfer actions (48) by virtue of, for each of the removal/setting-down locations, one or more of the transfer positions (46) in the picking zone (14) being selected as setting-down/removal location and being assigned thereto, wherein the setting-down/removal location is situated within an action zone (72) which extends around the respective removal/setting-down location and which moves dynamically with the respective manipulator (40); generating (S14) an action order for each of the manipulators (40) by virtue of: some of the transfer actions (48) being selected; and an in particular unidirectional movement path (74) being defined along which the respective manipulator (40) moves between the selected removal/setting-down locations through preferably the entire picking zone (14); and generating (S16) transport orders for the FTF (20) such that each of the manipulators (40) can, during an execution of the action order thereof, perform the transfer actions (48) thereof within the action zone (72) thereof, preferably without interruption.