Automated Pallet Mover Control for Dynamic Warehouse Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor belt systems in warehouses often clog when handling large numbers of pallets and are inflexible in modifying transport paths, leading to inefficiencies and increased operational costs.
Innovation Solution
Implementing automated guided vehicles (AGVs) with optimized algorithms to navigate and transport pallets, allowing for dynamic route selection and real-time adjustments based on changing conditions, replacing the need for complex conveyor belt systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conveyor belt system is used to transport pallets between loading/unloading area and storage area, then pallets can be conveyed concurrently from different start locations to different end locations, but the system clogs when a large number of pallets are conveyed at the same time
Solution Approach 1:
The patent divides the continuous conveyor belt system into discrete automated guided vehicle (AGV) units. Each AGV independently transports pallets between locations, eliminating the clogging problem that occurs in continuous conveyor systems when handling large volumes of pallets. The segmentation allows for better flow management and reduces bottlenecks.
Solution Approach 2:
The patent implements dynamic route selection and real-time adjustments for AGVs based on changing warehouse conditions. Unlike fixed conveyor belt paths, AGVs can dynamically modify their routes to avoid congestion and optimize transportation efficiency, preventing system clogging while maintaining high productivity.
2Productivity
If a conveyor belt system is installed to transport pallets, then pallets can be moved between different locations, but the system is inflexible in creating and modifying paths
Solution Approach 1:
The patent employs dynamic path planning algorithms that allow AGVs to adapt their routes in real-time based on warehouse reconfigurations, changing operational requirements, or obstacles. This provides the flexibility to modify transportation paths without physical infrastructure changes, unlike fixed conveyor belt systems.
Solution Approach 2:
The patent changes the fundamental parameter of path rigidity by replacing fixed conveyor belts with programmable AGVs. The digital control parameters of AGVs can be easily modified to create new paths or adjust existing ones, providing adaptability while maintaining transportation productivity.
3Productivity
If multiple automated guided vehicles operate concurrently in the physical space, then pallet transportation efficiency is improved, but collisions between vehicles may occur
Solution Approach 1:
The patent implements a control system with real-time feedback mechanisms that monitor AGV positions, speeds, and routes. The system continuously adjusts vehicle operations based on feedback from sensors and tracking systems, enabling collision avoidance while maintaining high concurrent operation levels for improved productivity.
Solution Approach 2:
The patent uses preliminary route planning and coordination algorithms that assign paths to AGVs before they depart. The control system pre-coordinates vehicle movements and identifies potential collision risks in advance, allowing multiple AGVs to operate concurrently safely by preventing conflicts before they occur.
Data Source
AI summary
An automated warehouse system can include automated pallet movers, a physical space in which the automated pallet movers operate, and a control system to provide commands to each of the automated pallet movers for operating in the physical space. The commands can include a pallet transportation command including a pallet identifier of a pallet to be transported by the automated pallet mover in the physical space, and a destination location to which the pallet is to be transported by the automated pallet mover. The commands can also include a control algorithm command that specifies a control algorithm for moving through the physical space. The automated pallet mover can be configured to transport the pallet to the destination location according to a route resulting from performance of the control algorithm, while other automated pallet movers concurrently transport other pallets to other destination locations.