Overhead Conveyor Order Picking with Batch Buffer Sorting
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Solution Overview
Problem
Existing logistics and picking systems are inflexible and space-intensive, particularly when dealing with varying quantities and types of goods, as they require significant space for transport, storage, sorting, and packing, and are inefficient in merging objects into orders.
Innovation Solution
A monorail system with trolleys, batch buffers, packing stations, and identification devices that manage trolleys and goods as units, allowing for flexible sorting and storage of orders in a space-saving manner by pre-sorting goods in batch buffers and efficiently routing them to packing stations based on order completion criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If existing logistics and picking systems are used, then goods can be transported and sorted, but a large amount of space is required for transport, intermediate storage, sorting, and unpacking and packing
Solution Approach 1:
The system transitions from ground-level operations to three-dimensional space utilization by implementing an overhead conveyor system with monorails operating above the warehouse floor. This vertical dimension expansion allows transport and sorting operations to occur in previously unused aerial space, dramatically reducing ground space requirements while maintaining operational flexibility for various goods types and order quantities
2Productivity
If existing sorting systems are used, then objects can be sorted into groups, but the individual sorting conveyor circuits have to work together and are largely blocked for other orders, which is time-consuming
Solution Approach 1:
The system implements preliminary sorting actions at multiple intermediate stopping points along the monorail route. Instead of waiting until all items are collected before sorting begins, the system performs incremental sorting operations as items pass through different zones, allowing parallel processing and eliminating the blocking effect that occurs in sequential sorting systems
Solution Approach 2:
The sorting process is divided into multiple independent segments or stopping points along the monorail path. Each segment can independently sort items for different orders, allowing simultaneous sorting operations for multiple orders without blocking each other, thereby dramatically improving throughput and reducing overall processing time
3Adaptability or versatility
If existing systems are designed specifically for certain goods and material flows, then those specific goods can be handled efficiently, but the systems are not very flexible if the type or quantity of goods changes significantly
Solution Approach 1:
The overhead conveyor system with monorails and trolleys is designed as a universal platform that can handle diverse goods types and quantities through standardized interfaces. The system uses adjustable racks, modular trolleys, and programmable routing that can be reconfigured for different product assortments and order requirements, providing flexibility without requiring complete system redesign for each application scenario
Data Source
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AI summary
The present invention relates to a method and a corresponding overhead conveyor system for order picking with at least one item assigned to each order and/or for returns management. The system comprises an overhead conveyor with trolleys, as well as loading stations (1), a batch buffer (8) with multiple sections (9), and packing stations (12), wherein the trolleys and the items have identification devices. A trolley is fed to a loading station (1) and identified, and then packed with an identified item at the loading station (1). The trolley and item identifications are linked in a management system. The trolley is fed to a section (9) of the batch buffer (8) or a returns buffer (15) and, coming from the loading station (1) or the returns buffer (15), is stored in the section (9) of the batch buffer (8), sorted according to the associated order but optionally chaotically with respect to multiple orders.Once all goods for the order are fully stored in the batch buffer (8), all trolleys containing the order's goods are transferred to a packing station (12). When the goods are separated from the trolley, the identification of the goods and/or the trolley is recorded, and the management system subsequently manages the goods and the trolley separately.