Automated Picking System for Flat-Pack Articles
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Solution Overview
Problem
Existing automated order picking systems are unsuitable for picking flat-pack items, as they either lack the throughput or require manual handling, and are not efficiently integrated with existing racking systems.
Innovation Solution
A system comprising a rack with storage locations, a gantry robot, conveyors, and a controller to automate the picking process, allowing direct transfer of items from source pallets to target pallets using a packing pattern, with decoupled depalletizing and palletizing processes, and minimal space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional automated order picking systems are used, then automation is achieved, but throughput is insufficient and they cannot handle flat-pack items
Solution Approach 1:
The system segments the picking process into independent depalletizing and palletizing operations performed by separate gantry robots. This allows parallel processing where multiple source pallets can be depalletized simultaneously while items are being sorted and placed on target pallets, significantly increasing throughput compared to sequential operations in traditional systems
Solution Approach 2:
A buffer zone is introduced as an intermediary between the depalletizing gantry robot and the packing gantry robot. This buffer temporarily stores items that have been depalletized but not yet sorted for current orders, allowing the packing robot to continuously access items without waiting for new depalletizing operations, thereby maintaining high throughput
2Productivity
If direct picking from source pallets to target pallets is implemented, then throughput increases, but integration with existing racking systems becomes complex
Solution Approach 1:
The conveyor system is designed with universal receiving positions that can accommodate multiple source pallets simultaneously, and discharge positions that can serve multiple packing operations. This multi-functional design allows the same conveyor infrastructure to support both direct picking operations and buffer operations, reducing integration complexity while maintaining high throughput
Solution Approach 2:
The system utilizes vertical space by positioning receiving positions at different heights within the rack structure. This dimensional approach allows multiple conveyors to operate independently without horizontal interference, enabling direct picking from multiple source pallets simultaneously while integrating with existing vertical rack systems
3Productivity
If multiple gantry robots are used for depalletizing, then throughput increases, but space requirements increase
Solution Approach 1:
Multiple gantry robots are positioned to share a common buffer zone and packing area. The depalletizing robots and packing robot operate in coordinated fashion around shared infrastructure, merging their functional zones to achieve high throughput without proportionally increasing the total space required. The buffer zone serves as a shared resource that all robots can access
Data Source
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AI summary
A method and a system (10) for picking articles (12), in particular flat-pack articles (12), according to picking orders are disclosed, wherein the system comprises: a rack extending substantially along a longitudinal and vertical direction of the system and having a plurality of storage locations configured to store source pallets; a first gantry robot with a handling unit configured to transfer the articles; a packing position configured to buffer a destination pallet; a plurality of conveyors; and a control system preferably configured to determine an order-specific packing pattern for each of the orders in order to automatically feed several of the articles from one or more of the source pallets to the packing position by the first gantry robot according to the respective order;wherein each of the conveyors has a receiving position located within the rack and configured to receive the source pallets, and a discharge position located within an action area of the first gantry robot and configured to provide the source pallets, preferably dynamically; wherein the control system is further configured to transport source pallets from the storage locations via the receiving positions to the discharge positions, which contain the items required to pack the items onto the target pallet according to the respective packing pattern; wherein the first gantry robot defines the action area within which the handling unit is movable and which contains at least the discharge positions of the conveyors;and wherein the first gantry robot is configured to pick up the items required for packing according to the respective packing pattern from the source pallets at the delivery positions and deliver them to a packing position feed conveyor which extends through the action area and which is connected to the packing position with respect to a material flow, wherein the packing position is positioned within an action area of a second gantry robot which is directly connected to the rack via further conveyors, or wherein the packing position is positioned outside the action areas of the gantry robots.