Mobile Confirmation Unit for Order Picking Workstations
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Solution Overview
Problem
Existing order-picking systems require manual confirmation actions that disrupt the operator's motion sequence, leading to ergonomic disadvantages and inefficient energy usage, as well as the risk of erroneous triggering at neighboring workstations due to non-fixed assignments between mobile transmission units and devices.
Innovation Solution
A workstation with a remote control element featuring a coupled wireless data communication connection between a base station and a mobile unit, allowing the operator to position the mobile unit for easy reach and ensuring correct workstation assignment, with energy management to enable long-term operation through only active communication during actuation, using a packet-based radio connection and a microcontroller with an electric contactor and energy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a confirmation control element is arranged at a handily placed position centered between load carriers, then ease of operation is improved, but the motion sequence of the operator is disturbed and additional time is required
Solution Approach 1:
The confirmation control element is extracted from the stationary workstation and integrated into a mobile transmission unit that the operator can carry. This removes the control element from the path of the circular motion sequence between source and target containers, allowing the operator to confirm picking operations without interrupting their natural workflow. The mobile unit can be positioned anywhere within communication range of the base station at the workstation.
Solution Approach 2:
The confirmation control element transitions from a fixed stationary position to a dynamic mobile position carried by the operator. This dynamic arrangement allows the control element to move with the operator throughout the workspace, eliminating the need to return to a central fixed location for confirmation, thereby reducing motion disruption and time loss.
2Ease of operation
If a mobile transmission unit is used for confirmation, then ease of operation is improved, but energy consumption increases due to continuous operation
Solution Approach 1:
The wireless data communication connection in the mobile transmission unit is activated periodically only when needed for confirmation actions, rather than continuously. The connection is established temporarily during actuation of the actuating element and closed afterward, creating a periodic on-demand communication pattern that significantly reduces energy consumption while maintaining full operational functionality.
Solution Approach 2:
The communication connection parameter changes from a continuous state to a temporary on-demand state. The system dynamically adjusts the connection duration and frequency based on actual confirmation needs, transitioning the communication mode to match the operational rhythm of picking confirmations, thereby optimizing energy usage.
3Ease of operation
If a mobile transmission unit is used without fixed assignment, then ease of operation is improved, but reliability decreases due to risk of erroneous triggering at neighboring workstations
Solution Approach 1:
The base station at each workstation provides feedback by evaluating data telegrams received from mobile units and verifying workstation assignment before triggering confirmation actions. This feedback mechanism ensures that only properly assigned confirmations are processed, preventing erroneous triggering at neighboring workstations while maintaining the mobility and ease of operation of the transmission unit.
Solution Approach 2:
The base station acts as an intermediary between the mobile transmission unit and the process controller. It receives and evaluates data telegrams, verifies workstation assignment, and only then triggers the confirmation action. This intermediary layer provides a safety check that prevents erroneous triggering while allowing the mobile unit to operate freely within communication range.
Data Source
AI summary
At a workstation for an order-picking system, with a remote control device are a source load carrier, and a target loading aid of a picking order, wherein the operator reloads at least one article unit according to an order. By actuating a confirmation control element, the operator indicates the completed reloading to a process controller of the workstation, which is configured to trigger a step following the current order. The confirmation control element has a base station and a mobile unit, between which a coupled wireless data communication connection is established. The mobile unit has an actuating element with an electric contactor, an electric energy storage, and a micro controller with a communication interface. Moreover, the data communication connection is only established during an actuation of the actuating element and the transmission of the data telegram.