Optical Scanner and Conveyor for High-Speed Order Selection
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Solution Overview
Problem
Current material handling systems in the warehousing and distribution industry face challenges such as slow order selection speed, inefficiency in handling a wide variety of item sizes, high energy consumption, and the need for excessive physical space, as well as difficulties in software integration and implementation costs.
Innovation Solution
The use of PLC-controlled discharge conveyors with a Self-Controlled Sheetfeed Optical Recognition Scanner, which modifies order selection forms to barcode or OCR fonts, allowing for efficient item detection and conveyance, reducing energy consumption, and optimizing space usage through modular cubical arrangements, enabling a high-speed order selection process without major software changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional order selection methods are used, then system complexity is low, but order selection speed is slow
Solution Approach 1:
The patent replaces manual mechanical order selection with an automated optical recognition system. The scanner reads barcodes on items, automatically identifies them, and directs conveyors to deliver items to packing stations, eliminating manual searching and selection while maintaining relatively simple system architecture.
Solution Approach 2:
The system enables self-service order selection where items convey themselves to the correct packing station based on automated identification. The optical scanner and conveyor system work autonomously to route items without human intervention, significantly increasing selection speed while keeping control logic straightforward.
2Area of stationary object
If traditional material handling systems are used, then energy consumption is moderate, but physical space requirements are excessive
Solution Approach 1:
The patent transitions from horizontal material handling to vertical three-dimensional space utilization. Items are conveyed vertically to packing stations located at different heights, allowing the system to fit within a compact footprint while maintaining efficient item flow and reducing overall facility space requirements.
Solution Approach 2:
The conveyor system operates with periodic start-stop cycles, moving items only when needed to specific packing stations rather than continuous operation. This reduces energy consumption while maintaining compact physical dimensions, as the system activates only during active order fulfillment periods.
3Adaptability or versatility
If item-on-demand systems are implemented, then handling diversity of item sizes is improved, but system complexity increases
Solution Approach 1:
The patent implements a universal conveyor and packing station system that can handle multiple item types and sizes through a single integrated platform. The optical recognition system identifies various items by barcode, and the conveyor mechanism adapts to transport different dimensions, eliminating the need for multiple specialized systems and actually reducing overall complexity.
Data Source
AI summary
An order selection process is provided for the selecting of a plurality of a predetermined item or items from a stocked picking location in an order selection system. This process includes a method for converting a computer generated order selection form (pick ticket), a method and device for reading the order selection form (pick ticket), and a method for communication with a plurality of discharge conveyors.