Horizontal Order-Picker Automatic Positioning Control
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Solution Overview
Problem
Conventional horizontal order-pickers are inefficient due to excessive time spent traveling between pick-up points and order-picking containers, which is not compliant with safety regulations in Germany and Europe, leading to significant cost savings opportunities being missed.
Innovation Solution
A horizontal order-picker with an operating platform and load section that automatically moves a predetermined distance upon driver control, reducing the distance between pick-up points and order-picking containers, allowing the operator to efficiently position containers near pick-up points while ensuring safety compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the operator manually positions the order-picking container near the pick-up point, then the commissioning efficiency is improved, but the operator must repeatedly travel between the pick-up point and the container, increasing travel time and reducing productivity
Solution Approach 1:
The order-picker performs the positioning function automatically through a control unit that calculates the required travel distance based on sensor data about the pick-up point location and moves the vehicle accordingly. This self-service capability eliminates the need for the operator to manually position containers, resolving the contradiction by improving commissioning efficiency while eliminating the time-consuming repeated travel between pick-up points and containers.
Solution Approach 2:
The patent replaces the manual mechanical positioning process with an automated control system that uses sensors to detect the pick-up point, calculates the required distance, and automatically navigates the order-picker. This substitution of manual operation with an automated control system resolves the contradiction by maintaining high commissioning efficiency while eliminating operator travel time.
2Productivity
If the vehicle travels automatically without driver intervention, then the operator can perform commissioning tasks simultaneously, but this conflicts with safety regulations in Germany and Europe that require driver control
Solution Approach 1:
The system dynamically adapts the level of automation based on the operational phase: during normal operation, the control unit automatically calculates and executes positioning maneuvers to maximize productivity; when safety regulations require driver control, the system transitions to manual mode. This dynamic adjustment resolves the contradiction by allowing automated efficiency improvements while maintaining compliance with safety regulations through selective manual intervention.
3Loss of time
If the order-picker moves to reduce the distance between pick-up point and container, then commissioning time is reduced, but the vehicle must precisely calculate and execute the movement distance based on offset measurements
Solution Approach 1:
The control unit receives feedback from sensors that detect the pick-up point location and the current position of the order-picker. Based on this feedback, the control unit calculates the precise travel distance required to position the container at the optimal location and executes the movement. This feedback loop resolves the contradiction by reducing commissioning time through automated positioning while managing control system complexity through a straightforward sensor-control-execution architecture.
Data Source
AI summary
A horizontal order picker with an operating platform and a load section which is provided for accommodating at least one order-picking container, wherein an operational control is provided in the operating platform, upon actuation of which the horizontal order picker moves for a predetermined distance (D) automatically, the length of the distance (D) corresponding to the offset between the operating platform and one of the order-picking containers.