Grid-Moving Robotic Picking for Direct Bin-to-Container Fulfillment
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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, which restricts the speed and efficiency of customer order compilation.
Innovation Solution
A robotic picking device that moves laterally on a grid-patterned rail system above storage bins, equipped with picking means to directly retrieve inventory items from bins and transfer them to delivery containers, reducing the need for manual handling and optimizing bin handling processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used at pick stations, then flexibility in handling different products is maintained, but system speed and productivity are reduced
Solution Approach 1:
The robotic picking system enables self-service by allowing robots to autonomously navigate, locate, and retrieve products from storage bins without human intervention. The system uses automated vision systems and navigation algorithms to independently complete picking tasks, eliminating the need for manual labor at pick stations while maintaining operational flexibility.
Solution Approach 2:
The patent replaces manual mechanical operations with automated robotic systems. Robots equipped with sensors, vision systems, and automated grippers substitute human workers, performing product retrieval, sorting, and delivery tasks automatically. This mechanical substitution dramatically increases picking speed while reducing labor requirements.
2Area of stationary object
If complex hoisting mechanisms are used to access stacked containers, then vertical storage space is utilized, but system cost and complexity increase
Solution Approach 1:
Instead of using complex vertical hoisting mechanisms to access stacked containers, the patent transitions to horizontal movement along the top surface of stacks. Robots travel laterally on rails or tracks positioned at the top of storage areas, accessing containers by moving horizontally rather than vertically. This dimensional change simplifies the mechanism while maintaining high storage density.
Solution Approach 2:
The patent extracts the hoisting function from the system by eliminating vertical lifting mechanisms entirely. Containers are accessed at their original vertical positions through horizontal robot movement, removing the need for complex hoisting equipment while preserving stack-based storage efficiency.
3Productivity
If pick stations are expanded to handle more products, then picking capacity increases, but congestion and space requirements increase
Solution Approach 1:
The patent segments the centralized pick station into distributed picking points along the storage racks. Instead of consolidating all picking activities at one location, multiple robotic picking stations are distributed throughout the storage area, each handling specific product zones. This segmentation eliminates congestion at single points while increasing overall picking capacity.
Solution Approach 2:
The system transitions from vertical stacking of pick stations to horizontal distribution along the top surfaces of storage stacks. Robots operate at the same vertical level, moving laterally across multiple storage faces, which eliminates the need for multi-level vertical pick station arrangements and reduces overall space requirements.
Data Source
AI summary
A robotic picking device for picking items from a containerised storage system wherein items are stored in storage bins in stacks within a framework having a grid system disposed above the stacks of bins. Robotic picking devices are disposed on the grid, the devices acting 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.