Gantry Robot Flatpack Picking System
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Solution Overview
Problem
Existing automated picking systems are not suitable for picking flatpack items efficiently, as they often require a picking buffer and are not designed to handle heavy and bulky items directly from source pallets.
Innovation Solution
A fully automated system that uses gantry robots to pick items directly from source pallets, with short transport routes and minimal space requirements, eliminating the need for a picking buffer and enabling efficient handling of flatpack items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a picking buffer with individual trays is used (as in high-bay warehouse systems), then articles can be stored and retrieved, but the system cannot handle flatpack items efficiently and requires complex depalletizing operations
Solution Approach 1:
The invention extracts the picking buffer concept entirely from the system. Instead of using individual trays as a buffer, the system performs direct picking from source pallets to target containers, eliminating the need for depalletizing operations and intermediate storage of individual items.
Solution Approach 2:
The invention merges the storage and picking functions into a single operational step. Source pallets are positioned directly at picking stations where robots can access items for both storage retrieval and order fulfillment simultaneously, eliminating separate depalletizing and buffer operations.
2Extent of automation
If gantry robots are used to pick individual items from depalletized towers, then automated picking is achieved, but the throughput is low and the system is not suitable for flatpack items
Solution Approach 1:
The system uses multiple gantry robots operating in parallel at different picking stations, each handling a portion of the total picking workload. This distributed approach increases overall throughput while maintaining full automation, allowing the system to handle high-volume orders efficiently.
Solution Approach 2:
The picking system is segmented into multiple independent picking stations with dedicated gantry robots. Each robot operates autonomously at its own station with direct access to source pallets, allowing simultaneous processing of multiple orders and increasing total system throughput.
3Ease of operation
If source pallets are transported through a complex branched conveyor network, then articles can be delivered to picking areas, but the space requirement is large and transport times are increased
Solution Approach 1:
Instead of bringing individual items from remote storage locations to picking stations via complex conveyors, the system inverts the approach by bringing entire source pallets to the picking stations. This reversal eliminates the need for intermediate buffering and complex conveyor networks, reducing space requirements and transport times.
Solution Approach 2:
Source pallets are prepared and positioned in advance at the picking stations before picking operations begin. This preliminary positioning of complete pallets at the point of use eliminates the need for complex real-time conveyor routing and reduces transport distances during actual picking operations.
4Productivity
If a picking buffer is used between pallet warehouse and picking zone, then articles can be staged for picking, but flatpack items are unsuitable for this concept and ergonomic challenges arise
Solution Approach 1:
The system introduces robotic manipulators as intermediaries between the source pallets and the picking process. These robots handle all interactions with flatpack items, eliminating the need for human workers to manually handle awkward flatpack items, thus resolving ergonomic challenges while maintaining high picking performance.
Solution Approach 2:
The invention replaces manual mechanical handling of flatpack items with automated robotic systems. Robots with specialized end-effectors are used to grasp, move, and position flatpack items, substituting human mechanical interaction with automated mechanical systems that are not constrained by ergonomic limitations.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The invention relates to a method and a system (10) for picking articles (12), more particularly flatpack articles (12), in accordance with picking orders, the system (10) comprising: - a rack (24), which extends substantially in a longitudinal and a vertical direction (X, Y) of the system (10) and which has a plurality of storage spaces (30) designed for storing source pallets (30); - a gantry robot (36), which has a manipulation unit (37) and which is designed to transfer the articles (16); - a packing position (62), which is designed for the buffering of a target pallet (34); - a plurality of conveyors (38); and - a controller (74), which is preferably designed to determine, for each of the orders, an order-specific packing pattern in order to pack a plurality of the articles (12) according to the order in question from one or more of the source pallets (30) onto a target pallet (34) in the packing position (62) by means of the gantry robot (36) in an automated manner; wherein: each of the conveyors (38) has a receiving position (66), which is positioned within the rack (24) and is designed to receive the source pallets (30), and a dispensing position (58), which is positioned within an action space of the gantry robot (36) and is designed to provide the source pallets (30), preferably dynamically; the gantry robot (36) defines the action space, within which the manipulation unit (37) can be moved and which contains the packing position (62) and the dispensing positions (58) of the conveyors (38); and the controller (74) is also designed to cause those of the source pallets (30) that comprise the articles (12) that are needed for the packing in accordance with the packing pattern in question to be transported from the storage spaces (32), via the receiving positions (66), to the dispensing positions (58).