Automated Order-Picking Container for Flexible Packaging
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Solution Overview
Problem
Current methods for packing and shipping items, especially for orders with few items, require significant manual labor and result in inefficient use of materials, leading to high material consumption and unnecessary transport volume.
Innovation Solution
A fully automated method and system for consolidated order picking and packaging using dynamic picking containers that can be identified via barcodes or RFID, where items are automatically transferred into transport packaging like paper or plastic bags, reducing the need for manual labor and optimizing packaging volume based on item size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual packing methods are used with decentralized workstations, then employees can pack items into transport containers, but the labor requirements increase significantly and throughput decreases
Solution Approach 1:
The patent replaces manual mechanical packing operations with an automated picking robot system that uses sensors, conveyors, and robotic manipulators to automatically retrieve items and place them into transport containers, eliminating the need for manual labor while significantly increasing throughput capability
Solution Approach 2:
The system enables self-service packing where the automated robot system independently identifies orders, retrieves required items from storage locations, and packs them into appropriate transport containers without human intervention, making the packing process autonomous and highly efficient
2Reliability
If rigid transport packaging like boxes and cartons is used, then items are protected during transport, but material consumption increases and transport volume becomes unnecessarily large
Solution Approach 1:
The patent employs flexible transport containers such as bags made from flexible materials instead of rigid boxes and cartons, allowing the packaging to conform to the actual volume of items while providing adequate protection during transport, thereby reducing material consumption and transport space utilization
Solution Approach 2:
The system dynamically selects and adjusts packaging parameters by choosing between different types of flexible containers based on item characteristics and order requirements, optimizing the packaging volume to match the actual cargo volume and minimizing excess material use while maintaining transport safety
3Reliability
If sufficient filler material is added to packaging, then items are protected from damage during shipping, but the packaging volume increases unnecessarily
Solution Approach 1:
The use of flexible transport containers allows the packaging to adapt its shape and volume to closely match the items being packed, eliminating the need for excessive filler material while still providing protection during transport, as the flexible container conforms to the item contours
Solution Approach 2:
The packaging system dynamically adapts to the cargo by using flexible materials that can deform and conform to the actual volume and shape of items, rather than requiring fixed rigid containers with excessive empty space, thereby reducing overall packaging volume while maintaining protective functionality
4Productivity
If automated picking systems with picking robots are used, then the throughput can be increased, but the system complexity increases
Solution Approach 1:
The automated picking system is divided into distinct functional modules including item retrieval stations, conveyors, picking robots, and packing stations, allowing each component to be independently optimized and maintained while working together to achieve high throughput with manageable system complexity
Solution Approach 2:
The picking robot system is designed with universal components that can handle multiple item types and order configurations, using standardized grippers, sensors, and control mechanisms that perform multiple functions across different packing scenarios, thereby achieving high productivity without proportionally increasing system complexity
Data Source
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AI summary
The present invention relates to a method and a system for automatically consolidating order-picking and packing of articles (A) ready to send. An order-picking container (1), in which articles (A) are grouped according to an order, is provided. The method comprises the steps of: a) arranging the order-picking container (1) on a predetermined transfer location (10) and transferring an article (A) to the order-picking container (1), b) moving the filled order-picking container (1) to a predetermined packing station (20) and providing, upstream of the packing station (20), a transport packaging (100) with a downwardly facing opening (101) which is adapted to receive the order-picking container (1), c) arranging the order-picking container (1) through the opening (101) in the transport packaging (100), d) moving the filled order-picking container (1) which is arranged in the transport packaging (100) to a transfer and separating station (30), e) transferring the at least one article (A) from the order-picking container (1) in the transport packaging (100) by means of a vertical turning movement, f) separating the order-picking container (1) from the transport packaging (100) in which at least one article (A) is arranged and g) closing the transport packaging (100). All method steps are carried out automatically in a machine in a continuous process. The invention also relates to an order-picking container (1).