Automated Pallet Mover Routing for Concurrent Warehouse Traffic
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Solution Overview
Problem
Conventional conveyor belt systems in warehouses often clog when handling multiple pallets simultaneously and are inflexible in modifying transport paths, leading to inefficiencies and increased operational costs.
Innovation Solution
Implementing automated guided vehicles (AGVs) with optimized algorithms for route planning and lane management, allowing for dynamic path adjustments and concurrent pallet transportation, which reduces collisions and enhances throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conveyor belt system is used to transport multiple pallets concurrently, then productivity increases, but the system clogs and reliability decreases
Solution Approach 1:
The system divides the warehouse transportation space into multiple defined lanes, with each lane serving as an independent pathway for pallet movers. This segmentation prevents pallets from different routes from interfering with each other, eliminating clogging while maintaining high throughput capacity.
Solution Approach 2:
The system dynamically assigns routes and lanes to pallet movers based on real-time conditions, optimizing traffic flow. The control algorithm continuously adjusts lane assignments and routing decisions to prevent congestion and maintain reliable operation under varying workload conditions.
2Ease of manufacture
If conventional conveyor belts are used, then initial setup is simple, but adaptability to modify transport paths is poor
Solution Approach 1:
The system uses software-defined lanes and dynamic route planning algorithms that can be modified without physical reconfiguration. Transport paths can be changed by updating the control algorithm's lane definitions, providing high adaptability while maintaining the simplicity of a flat-floor warehouse layout.
Solution Approach 2:
The patent replaces the mechanical conveyor belt infrastructure with automated guided vehicles that navigate using sensors and control algorithms. This substitution eliminates the need for physical path modifications, as routing changes are achieved through software updates rather than mechanical reconfiguration.
3Productivity
If more pallet movers are deployed to increase productivity, then throughput improves, but collision risk increases
Solution Approach 1:
By dividing the workspace into dedicated lanes and assigning specific routes to individual pallet movers, the system enables multiple vehicles to operate concurrently without conflict. Each vehicle operates in its assigned lane with predictable movement patterns, allowing safe deployment of additional movers to increase capacity.
Solution Approach 2:
The control algorithm continuously monitors the positions and statuses of all pallet movers, using feedback to dynamically adjust routing and timing. This real-time coordination prevents collisions even as the number of active movers increases, maintaining safety while scaling productivity.
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.