Moving Tote Transfer Station for Asynchronous Order Picking
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Solution Overview
Problem
Current robotic retrieval and delivery systems in warehouses and similar environments are inefficient in fulfilling orders asynchronously, leading to delays and increased operational costs as they lack a fully automated and synchronized method for item retrieval and delivery.
Innovation Solution
A system comprising a first mobile robot for carrying a shelf tote, a second mobile robot for carrying an order tote, and a transfer station with a picker having two degrees of freedom, along with a control system that coordinates the movement and item transfer between the robots, enabling asynchronous order fulfillment by dispatching robots to pick up items from shelves and transfer them to order totes during transit through the transfer station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional robotic retrieval and delivery systems are used, then automation is provided, but order fulfillment efficiency is low and processing delays occur
Solution Approach 1:
The system performs preliminary actions by having the first robotic carrier pick up the shelf tote in advance and bring it to the transfer station before the second robotic carrier arrives with the order tote. This preliminary positioning enables immediate item transfer upon arrival, eliminating waiting time and improving order fulfillment efficiency.
Solution Approach 2:
The system maintains continuity of useful action by coordinating the movement and transfer operations so that robots and totes are continuously engaged in productive activities. The asynchronous operation allows the first robotic carrier to continuously prepare shelf totes while the second carrier continuously delivers order totes, with transfers occurring without interruption at the transfer station.
2Speed
If manual intervention is used for item retrieval and delivery, then flexibility is maintained, but operational speed decreases
Solution Approach 1:
The system implements self-service through the autonomous coordination between the first and second robotic carriers. The robots independently navigate, pick up totes, transport them to the transfer station, and execute transfers without human intervention. The control system enables the robots to self-coordinate their movements and timing, achieving high-speed automated order processing.
Solution Approach 2:
The transfer station serves as an intermediary mechanism that facilitates automated item transfer between the first and second robotic carriers. This intermediary structure enables the exchange of items between shelf totes and order totes through the picker mechanism, maintaining full automation while enabling efficient item transfer without direct robotic arm interaction between carriers.
3Ease of operation
If synchronous coordination is used for robot operations, then precision is achieved, but system complexity increases
Solution Approach 1:
The control system simplifies coordination by having the first robotic carrier perform preliminary actions of picking up and transporting the shelf tote to the transfer station before the second carrier arrives. This preliminary positioning reduces the complexity of real-time synchronization, as the first carrier completes its preparation work in advance, and only simple transfer coordination is needed when the second carrier arrives.
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for fully automated order fulfillment. A method includes identifying a shelf tote having an item contained therein for transfer to an order tote; dispatching a first carrier to pick up the shelf tote and a second carrier to pick an order tote; causing the picker to pick the item from the shelf tote while the shelf tote is moving through the transfer station; and transferring the item to the order tote by the picker.