Intersecting Conveyor Picking Station for Continuous Goods-to-Man Flow
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Solution Overview
Problem
Existing picking systems according to the goods-to-man principle often require complex designs and compromise operational flexibility or throughput to improve ergonomics and picking performance.
Innovation Solution
Convey product and order load carriers at intersecting angles with individually controllable conveyors, allowing simultaneous movement and varying speeds, enabling 'on-the-fly' picking and putting operations without halting, and incorporating buffer positions and ergonomic access points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If product load carriers are conveyed on a first linear conveying system and order load carriers on a second linear conveying system arranged at an intersecting angle, then picking performance and ergonomics are enhanced with continuous high-speed exchange of load carriers, but the device complexity increases due to the need for individually controllable conveyors and coordinated movement
Solution Approach 1:
The conveying system is segmented into two independent linear conveying systems - one for product load carriers and another for order load carriers. Each system can be controlled independently, allowing them to operate at different speeds and be positioned at intersecting angles. This segmentation enables the complex picking operation to be divided into manageable, independently controllable segments that can be coordinated through a control device.
Solution Approach 2:
The patent transitions from a single-linear conveying arrangement to a two-dimensional intersecting conveying system. By arranging the product load carrier conveyor and order load carrier conveyor at intersecting angles, the system creates a spatial configuration that allows simultaneous movement of both carrier types through the picking station. This dimensional change enables continuous flow picking while maintaining ergonomic access points.
2Productivity
If load carriers are conveyed at varying speeds with simultaneous movement, then throughput is maintained and picking efficiency is improved, but the control system complexity increases
Solution Approach 1:
The conveying system is designed with dynamic speed control capabilities, allowing each linear conveying system to operate at varying speeds independently. The control device coordinates the movement of product load carriers and order load carriers, adjusting their speeds as needed to maintain continuous flow and optimize picking efficiency. This dynamic adjustment ensures that throughput is maintained while accommodating the different operational requirements of each carrier type.
3Productivity
If picking operations are performed without halting the conveyors, then continuous throughput is maintained, but the difficulty of performing accurate picking operations increases
Solution Approach 1:
The system maintains continuous movement of both product load carriers and order load carriers through the picking station without halting the conveyors. The intersecting angle arrangement and independent speed control allow picking operations to be performed on moving carriers, eliminating idle time and maintaining continuous throughput. The control device ensures that carriers are positioned optimally for picking while maintaining their movement, enabling uninterrupted operation.
Data Source
AI summary
A method for picking articles according to the goods-to-man principle at a picking station, in which articles are picked from product load carriers into order load carriers, the order load carriers are conveyed in a first row through the picking station, articles are presented in product load carriers and picking is carried out therefrom. The product load carriers are also conveyed in a second row through the picking station, the second row being arranged at an angle to the first row and picking taking place from a flow of product and order containers which are simultaneously conveyed through the picking station, to achieve a high throughput.