Coordinated Low-Base Movable Units for Dense Warehouse Picking
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Solution Overview
Problem
Conventional material handling systems, such as floor conveyors and fork-lift trucks, are limited in their ability to densify warehouses, especially in spaces where height cannot be increased, and require operators to perform multiple order picks efficiently while maintaining flexibility and maneuverability in narrow aisles.
Innovation Solution
A material handling system comprising multiple movable units with independent navigation and power sources, where one unit can be designated as a master to control others, allowing for coordinated operation and flexible navigation, including the use of wireless interfaces and scissor lifts for ergonomic operation, and compact design for efficient warehouse use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional floor conveyors and fork-lift trucks are used for order picking, then operators can perform multiple order picks, but the warehouse cannot be densified when height cannot be increased
Solution Approach 1:
The patent transitions from horizontal warehouse expansion to vertical utilization by enabling operators to work at elevated positions on movable units, effectively using the vertical dimension to increase storage density while maintaining order picking efficiency
Solution Approach 2:
The system divides the warehouse into multiple operational levels with movable units that can independently navigate and operate at different heights, allowing simultaneous order picking operations at various vertical positions
2Productivity
If conveyor systems with automatic transportation are applied, then goods transportation efficiency increases, but flexibility is highly disadvantageous
Solution Approach 1:
The patent employs movable units with independent navigation capabilities that can dynamically adapt their paths and positions, combining the efficiency of automated systems with the flexibility of manual operation, unlike fixed conveyor systems
Solution Approach 2:
Each movable unit is equipped with its own power source and navigation device, enabling autonomous operation and independent decision-making, which provides both efficiency and adaptability without requiring centralized control infrastructure
3Productivity
If longer forks are used to carry two pallets, then more orders can be picked at the same time, but maneuverability in narrow aisles deteriorates
Solution Approach 1:
Instead of using one long fork to carry two pallets, the system uses separate movable units that can independently transport individual pallets, maintaining narrow profile for maneuverability while enabling parallel operations to increase throughput
Solution Approach 2:
Multiple compact movable units operate in coordination to achieve the combined cargo capacity of longer forks, while maintaining the maneuverability advantages of smaller individual units in narrow warehouse aisles
4Productivity
If a master movable unit controls multiple slave movable units, then coordinated operation for transporting large amounts of goods is achieved, but system complexity increases
Solution Approach 1:
The master movable unit acts as an intermediary coordinator that manages slave units through standardized communication protocols, enabling complex coordinated operations while maintaining relatively simple individual unit designs and control logic
Data Source
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AI summary
Material handling system comprising a group of movable units, wherein each movable unit comprises a power source, a drive motor, a drive wheel powered by the drive motor, a stabilising support wheel, an object sensor for detecting objects in the surroundings of the movable unit, a wireless interface for contact with the other movable units of the system, a control unit, a navigation device, a load surface. Each movable unit has a limited base height comprised between 50 mm - 350 mm.