Automated Pallet Mover Control for Flexible Warehouse Routing
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Solution Overview
Problem
Conventional conveyor belt systems in warehouses often clog when handling a large number of pallets simultaneously and are inflexible in modifying transport paths, leading to inefficiencies and increased operational costs.
Innovation Solution
The implementation of automated guided vehicles (AGVs) that navigate through the warehouse using optimized algorithms to determine optimal routes, avoid collisions, and adapt to changing conditions, replacing the need for complex conveyor belt systems by defining virtual and marked lanes for efficient pallet transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyor belt systems are used to transport pallets between loading/unloading area and storage area, then pallet transportation can be automated, but the system clogs when handling large number of pallets simultaneously and is inflexible in modifying transport paths
Solution Approach 1:
The patent replaces fixed conveyor belt systems with dynamic automated guided vehicles (AGVs) that can autonomously navigate and adapt their routes. The AGVs use onboard sensors, controllers, and navigation systems to dynamically adjust their paths based on real-time warehouse conditions, eliminating the rigidity of fixed conveyor systems while maintaining automated transportation capabilities.
Solution Approach 2:
The patent substitutes the mechanical conveyor belt infrastructure with autonomous vehicles equipped with electronic navigation and control systems. This replacement enables flexible route modification through software updates and real-time decision-making algorithms, eliminating the physical constraints and modification difficulties inherent in traditional mechanical conveyor systems.
2Productivity
If complex conveyor belt systems with multiple connection points are deployed to handle concurrent pallet movements, then more pallets can be transported simultaneously, but the system becomes more complex and prone to clogging
Solution Approach 1:
The patent divides the pallet transportation function into independent automated guided vehicles, each capable of autonomous operation. Instead of a single complex conveyor system with multiple interconnection points, multiple independent AGVs navigate the warehouse space, reducing system complexity while maintaining the ability to handle multiple pallets simultaneously through parallel independent operations.
Solution Approach 2:
The automated guided vehicles serve multiple functions: they can transport pallets between any locations in the warehouse, navigate around obstacles, communicate with the central control system, and adapt to changing operational requirements. This multi-functionality replaces the need for specialized conveyor segments and connection points, simplifying the overall system architecture.
3Reliability
If conveyor belts are set up to create fixed transport paths, then pallet movement routes are established, but the system becomes less flexible in creating and modifying paths
Solution Approach 1:
The patent implements dynamic route planning through the controller system that receives real-time data from sensors and warehouse management systems. The controller dynamically calculates and updates optimal paths for each AGV based on current warehouse conditions, pallet destinations, and vehicle locations, enabling the system to maintain reliable transportation while adapting to changing requirements without physical reconfiguration.
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.