Order-picking system with overhead conveyor for independent article transport
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Solution Overview
Problem
Existing storage and order-picking systems face inefficiencies due to the need for large batch buffers, long dwell times, and complex control tasks, leading to increased processing times and space requirements, as well as dependencies between orders.
Innovation Solution
Implementing a method where articles are retrieved and transported individually and independently for each picking order, directly from the loading station to the sorting unit via an overhead conveyor system, eliminating the need for intermediate buffering and simplifying control tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If articles are retrieved and transported individually and independently for each picking order directly from the loading station to the sorting unit via overhead conveyor system, then processing time is reduced and space requirements are minimized, but the system requires precise synchronization and control of multiple independent transport operations
Solution Approach 1:
The system segments the transport process into independent individual operations for each picking order, allowing articles to be retrieved and transported separately rather than in batches. This segmentation enables parallel processing of multiple orders, reducing overall processing time while the control system manages each segment independently to avoid synchronization complexity
Solution Approach 2:
The overhead conveyor system acts as an intermediary transport mechanism between the loading station and sorting unit, providing a dedicated transport path that eliminates the need for intermediate buffering. This intermediary structure enables direct transport while the control system coordinates the conveyor operations to maintain system simplicity despite the increased number of independent transport operations
2Adaptability or versatility
If large batch buffers are used to accommodate multiple orders, then order buffering capability is improved, but space requirements and dwell time increase
Solution Approach 1:
The system extracts and eliminates the batch buffer component from the traditional order processing flow. Instead of using large batch buffers to accommodate multiple orders, the system retrieves and transports articles individually and independently for each order directly to the sorting unit. This extraction of the buffering function reduces space requirements while maintaining order processing capability through the overhead conveyor system's ability to handle multiple independent transport operations simultaneously
Solution Approach 2:
The overhead conveyor system enables continuous transport operations for multiple picking orders without requiring articles to wait in batch buffers. Each order's articles can be continuously transported from the loading station to the sorting unit as they are retrieved, eliminating dwell time associated with buffering while maintaining the system's ability to handle multiple orders adaptively
3Productivity
If batch processing is used for multiple orders, then order processing efficiency is improved, but dependencies between orders increase control complexity
Solution Approach 1:
The system segments order processing into independent individual operations, where each picking order is processed separately without creating dependencies between orders. The control system manages each order's transport operations independently through the overhead conveyor system, maintaining processing efficiency while avoiding the control complexity that would arise from managing inter-order dependencies in batch processing
Solution Approach 2:
The overhead conveyor system serves as an intermediary that enables independent transport operations for each order without requiring coordination between orders. This intermediary structure allows the control system to manage multiple orders independently, maintaining processing efficiency while reducing control complexity by eliminating the need to manage dependencies between batch-processed orders
Data Source
AI summary
A method for picking orders (22a . . . 22e) in a storage and order-picking system (1a, 1b) is provided, which comprises an article storage (2), a loading station (3), a sorting unit (4), a packing station (5), an overhead conveyor system (7a . . . 7f) and a control system (8). At the loading station (3), articles (22a . . . 22e) are transferred from a loading aid (23, 24, 25a . . . 25c) into a transport means (28a, 28b) and at the packing station (5) from a transport means (28a, 28b) into a shipping loading aid (30). In this regard, transporting an article (22a . . . 22e) out of the article storage (2) to the loading station (3) takes place individually and independently of the other picking orders for each picking order. Furthermore, transporting the transport means (28a, 28b) from the loading station (3) into the sorting unit (4) also takes place individually and independently of the other picking order and directly for each picking order. Furthermore, a storage and order-picking system (1a, 1b) for performing the method is provided.