Grid Storage Picking System with Dynamic Presentation Positions
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Solution Overview
Problem
Existing order picking systems face challenges such as high initial costs, difficulty in expansion, congestion at output ports, and limited ability to keep frequently required items at pick stations, leading to delays and increased load handler movements in grid-based systems.
Innovation Solution
A system combining grid-based storage with zone pick conveyor systems, featuring a framework with output columns and presentation positions for storage containers, allowing for dynamic repositioning of inventory items to optimize access and reduce congestion, using robotic load handling devices to move containers from stacks to presentation positions accessible by pickers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If grid-based storage systems with robotic load handlers are used, then storage density is improved, but congestion at output ports and delays in item retrieval occur
Solution Approach 1:
The system divides the storage area into multiple independently serviceable stacks, each with its own output port. This segmentation allows parallel operation of multiple load handlers, preventing congestion at any single output port while maintaining high storage density through vertical stacking arrangements.
Solution Approach 2:
The system implements preliminary positioning of storage containers at optimal locations before picking operations begin. Fast-moving items are pre-positioned at easily accessible locations, reducing the need for frequent load handler movements and minimizing congestion at output ports during order fulfillment.
2Productivity
If multiple pick stations and aisles are added to fulfilment systems, then order fulfillment capability is improved, but initial expenditure and system complexity increase
Solution Approach 1:
The pick stations are designed as multi-functional units that can service multiple stacks and handle various container types. Each pick station equipped with automated retrieval mechanisms can access items from different locations, eliminating the need for dedicated aisles and reducing overall system complexity while maintaining high order fulfillment capability.
Solution Approach 2:
Automated retrieval mechanisms serve as intermediaries between the high-density vertical storage stacks and the pick stations. These mediators enable access to stored items without requiring physical aisles, reducing infrastructure complexity while maintaining productivity.
3Quantity of substance
If load handlers are positioned to access deep stacks, then storage density is improved, but travel time and congestion increase
Solution Approach 1:
Deep stacks are divided into multiple zones with intermediate access points. Load handlers can service these zones sequentially or in parallel, reducing travel time while maintaining high storage density. Each segment can be independently accessed, preventing bottlenecks.
Solution Approach 2:
The system dynamically adjusts stack configurations and load handler routing based on real-time order requirements. Frequently accessed items are repositioned to shallower locations, while less frequent items remain in deep stacks, optimizing the balance between storage density and retrieval efficiency.
Data Source
AI summary
A system and method for picking items is disclosed. The system includes a grid-based storage area and an order assembly area. The system includes an array of presentation positions, the presentation positions being configured and adapted so as to present storage containers delivered to the presentation positions so as to enable picking of items contained therein.