Humanoid Robot and Lift Truck Coordination for Pallet Picking
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Solution Overview
Problem
Conventional warehouse workflows that incorporate human workers and autonomous robots face inefficiencies and safety hazards, such as the need for humans to walk long distances, lift heavy loads, and perform dangerous tasks at height, while also risking incorrect pallet construction due to lack of coordination between human and robotic operations.
Innovation Solution
Integrating humanoid robots with autonomous mobile robots (AMRs) to manage workflows, where a control system commands AMRs to move order pallets and humanoid robots to handle product transfer, ensuring proper layering and eliminating the need for human intervention in dangerous tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If human workers perform case pick-to-pallet tasks manually, then flexibility and adaptability are maintained, but labor intensity, safety risks, and incorrect pallet construction increase
Solution Approach 1:
The patent introduces an autonomous mobile robot as an intermediary device between the human worker and the pallet building task. The AMR transports cases to the worker and manages pallet construction according to WMS instructions, while the human focuses on picking. This mediation reduces labor intensity and improves pallet construction accuracy by separating transportation and assembly functions from manual labor.
Solution Approach 2:
The patent replaces the mechanical system of manual case handling and pallet construction with an autonomous mobile robot equipped with sensors, processors, and automated control systems. The AMR uses vision systems and RFID readers to identify cases, and automated mechanisms to place them correctly on pallets, eliminating the need for human workers to perform physically demanding and error-prone tasks.
2Loss of time
If autonomous mobile robots are used for pallet transportation, then walking distance and physical exertion are reduced, but coordination complexity and communication requirements increase
Solution Approach 1:
The autonomous mobile robot is designed with multi-functionality to handle various warehouse tasks including case transportation, pallet construction, and coordination with multiple systems (WMS, WCS, human workers). This universal design consolidates multiple functions into a single platform, reducing overall system complexity despite the robot's diverse capabilities.
Solution Approach 2:
The patent implements feedback mechanisms where the AMR continuously communicates with the WMS and human workers about its status, location, and pallet construction progress. The WMS provides real-time instructions and updates to the AMR, enabling dynamic coordination and reducing complexity through structured information flow and automated decision-making protocols.
3Adaptability or versatility
If human workers build pallets manually, then adaptability to different case configurations is maintained, but safety risks from heavy lifting and incorrect assembly increase
Solution Approach 1:
The patent replaces human manual operations with an autonomous mobile robot that uses sensors, vision systems, and automated mechanisms to handle cases and construct pallets. This substitution eliminates safety risks associated with heavy lifting and incorrect assembly while maintaining adaptability through programmable control systems that can adjust to different case configurations.
Solution Approach 2:
The AMR uses vision systems and RFID readers to create digital copies or representations of cases and their properties. This information is used to automatically determine correct pallet construction methods, ensuring safety and accuracy without requiring human workers to manually assess each case configuration.
4Length of stationary object
If conventional order picker lift trucks are used, then access to high storage locations is enabled, but human exposure to dangerous heights and driving risks remains
Solution Approach 1:
The patent introduces an autonomous mobile robot as an intermediary device that performs high-reach operations and case picking tasks. The AMR equipped with extended mechanisms or collaborative robots can access high storage locations without exposing human workers to dangerous heights, while still enabling retrieval of cases from elevated positions.
Solution Approach 2:
The patent replaces human-operated order picker lift trucks with autonomous mobile robots that use sensors, vision systems, and automated control to navigate and perform picking tasks. This substitution eliminates the safety hazards of driving at height while maintaining the capability to access high storage locations through automated navigation and manipulation.
Data Source
AI summary
Robotic systems and methods include one or more humanoid robots configured to move within a commercial environment; an autonomous order picker lift truck configured to move within the commercial embodiment; and a control system communicably coupled to the humanoid robots and the autonomous order picker lift truck. The control system is configured to perform operations including commanding the autonomous order picker lift truck to move a particular humanoid robot adjacent a particular donor pallet that is mounted on a rack assembly at or above a support surface of the commercial environment; commanding the autonomous order picker lift truck to move the particular humanoid robot to a vertical height at or near the particular donor pallet; and commanding the particular humanoid robot to pick a commercial product or a case from the particular donor pallet and place the picked commercial product or case to an order pallet or receiving pallet.