Grid Robotic Picking for Direct Bin-to-Delivery Transfer
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Solution Overview
Problem
Existing robotic picking systems for storage bins in stacked configurations face inefficiencies and high costs due to the need for manual intervention and complex hoisting mechanisms, leading to congestion and increased investment in pick stations.
Innovation Solution
A robotic picking system utilizing a grid pattern of tracks and uprights, where robotic picking devices can directly access and transfer inventory items from storage bins to delivery containers on the same grid, reducing the need for manual handling and optimizing bin usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual picking stations are used to transfer items from storage bins to delivery containers, then picking accuracy can be maintained, but system complexity and investment costs increase significantly
Solution Approach 1:
The system enables self-service picking where robotic load handlers automatically transfer items from storage bins to delivery containers without manual intervention. The robotic handlers navigate the grid, locate items using coordinate systems, and perform picking operations autonomously, eliminating the need for complex manual picking stations while maintaining high accuracy through automated control systems
Solution Approach 2:
The patent replaces traditional mechanical picking station infrastructure with mobile robotic load handlers that traverse overhead rails. Instead of fixed mechanical picking equipment, the system uses programmable robotic devices with sensors and automated gripping mechanisms to perform picking operations, reducing structural complexity while maintaining precision through electronic control
2Area of stationary object
If overhead rail systems are implemented for robotic load handlers, then storage space is optimized by eliminating ground-level aisles, but installation complexity and initial investment increase
Solution Approach 1:
The system transitions from ground-level horizontal movement to overhead three-dimensional movement. Robotic load handlers travel along elevated rails in the vertical dimension, allowing ground space to be fully utilized for storage bins and delivery containers. This spatial reconfiguration maximizes storage density while the modular rail design facilitates relatively straightforward installation compared to the value gained in space utilization
3Productivity
If multiple robotic load handlers operate on the same grid, then picking throughput increases, but coordination complexity and potential congestion increase
Solution Approach 1:
The system implements feedback control where each robotic load handler is equipped with sensors that continuously monitor its position, the locations of other handlers, and the state of storage bins and delivery containers. This real-time feedback enables dynamic route adjustment and collision avoidance, allowing multiple handlers to operate simultaneously on the same grid without congestion while maintaining high throughput through coordinated autonomous decision-making
Data Source
AI summary
A system for picking items from a containerised storage system is described. The items are stored in storage bins in stacks within a framework comprising a grid system disposed above the stacks of bins. Robotic devices are disposed on the grid, the devices acting so as to pick containers from the stacks of bins. The storage system is provided with at least one picking device for picking items from bins and depositing them directly in delivery containers DT.