Order Picking Sequencing with Article Group Buffer Sorting
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Solution Overview
Problem
Existing picking systems for sequencing articles are inefficiently operated despite being expensive due to sorting devices designed for the largest possible order, leading to suboptimal performance.
Innovation Solution
A multi-stage method and system that segments the overall article sequence into groups of a specifiable number, independent of order boundaries, optimizing the operation of sorting devices by aligning with the capacity of the second sorting device, and using retrieval and conveying systems to efficiently sequence and sort articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sorting devices are designed for the largest possible order, then the system can handle maximum capacity orders, but the devices operate inefficiently for smaller orders
Solution Approach 1:
The patent segments the article sequence into multiple groups, where each group corresponds to a specific sorting operation in the second sorting device. This segmentation allows the system to process smaller batches independently, enabling efficient operation of sorting devices designed for large capacity by utilizing them for multiple smaller sorting tasks rather than forcing single large-order processing.
Solution Approach 2:
The control computer performs preliminary actions by segmenting the overall article sequence into groups and determining optimal retrieval sequences before physical sorting occurs. This preliminary organization allows the sorting devices to operate efficiently by receiving pre-grouped articles, eliminating the need to handle entire large orders in single operations.
2Manufacturing precision
If articles are sorted individually through multiple sorting devices, then sequencing precision is improved, but system complexity and cost increase
Solution Approach 1:
The patent segments the sorting process into two distinct stages: first sorting device for initial grouping and second sorting device for final sequencing. This segmentation achieves high sequencing precision by dividing the complex sorting task into manageable stages, each handled by a dedicated device, rather than requiring a single complex device to perform all sorting functions.
Solution Approach 2:
The patent introduces buffer conveyor lines as intermediary elements between the first and second sorting devices. These buffer lines act as mediators that receive articles from the first sorting device and feed them to the second sorting device, enabling precise sequencing while distributing the complexity across multiple simpler components rather than a single complex system.
3Productivity
If the second sorting device is operated at maximum capacity, then productivity increases, but the complexity of coordinating article groups increases
Solution Approach 1:
The control computer performs preliminary segmentation of the article sequence into groups that match the maximum capacity of the second sorting device. This preliminary action ensures that when articles are fed to the second sorting device, they are already organized in optimal groups, allowing maximum capacity operation without increasing coordination complexity during the actual sorting process.
Solution Approach 2:
The control computer continuously monitors the operation of the first sorting device and buffer conveyor lines, adjusting the formation of article groups based on real-time capacity availability. This feedback mechanism enables the system to maintain maximum capacity utilization of the second sorting device while dynamically adapting to changing conditions, preventing coordination complexity from increasing.
Data Source
AI summary
A multi-stage system and method for sequencing articles in a picking system comprises a first sorting device with multiple buffer conveyor lines which are parallel in terms of conveyance and a downstream second sorting device. Acquired orders are lined up in a control computer of the picking system and subsequently segmented into article groups with a specifiable number of articles each, independent of order boundaries. For the sorting operation, article groups are selectively stored in the buffer conveyor lines and are subsequently conveyed to the second sorting device, where they are sorted, article group by article group, according to the order sequence.