Modular Pick Cell Buffering for Warehouse Robot Throughput
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Solution Overview
Problem
Conventional warehouse inventory transfer systems often result in idle time for robotic pickers due to mismatched inventory and conveyor systems, leading to inefficient handling and potential damage to items, with a need for optimized handling and buffering to maximize throughput and prevent damage.
Innovation Solution
A system of pick cells optimized for specific inventory types, each equipped with a robotic manipulator and end-of-arm tools tailored to handle specific item properties, along with a conveyor system that directs containers to the appropriate pick cell for efficient handling and buffering to prevent idling and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a conventional robotic picker is used with a conveyor system, then inventory transfer can be automated, but the robotic picker often waits on inventory or the inventory provided is not appropriate for the end of arm tool, leading to idle time and reduced productivity
Solution Approach 1:
The system divides the warehouse into multiple pick cells, each optimized for specific inventory types with appropriate end-of-arm tools. This segmentation allows parallel processing of different inventory types simultaneously, eliminating idle time caused by mismatches between robotic tools and inventory characteristics.
Solution Approach 2:
The conveyor system pre-sorts and positions inventory items before they reach the pick cells, ensuring that the correct inventory type arrives at the appropriate pick cell with the matching end-of-arm tool already ready. This preliminary preparation eliminates waiting time and keeps robotic manipulators continuously productive.
2Extent of automation
If inventory items are handled by generic robotic manipulators, then automation is achieved, but items may be damaged due to inappropriate handling methods
Solution Approach 1:
Each pick cell is equipped with end-of-arm tools specifically designed for the local characteristics of the inventory type it handles. For example, fragile items receive gentle gripping forces, while heavy items are handled with more robust tools. This localized optimization of tool characteristics prevents damage while maintaining automation.
3Device complexity
If buffer space is not incorporated in the system, then the system structure remains simple, but the robotic manipulator sits idle waiting for inventory and repetitive recirculation of high-frequency mover inventory occurs
Solution Approach 1:
Buffer spaces are strategically positioned within pick cells to pre-stage inventory items before they are needed for picking. This allows the robotic manipulator to continuously operate by picking from the buffer while new inventory is simultaneously replenished in the background, eliminating idle waiting time and reducing repetitive recirculation.
Data Source
AI summary
A system of inventory management is described. It includes at least one container adapted to hold inventory items. A conveyor system is adapted to move the containers to and from pick cells. Each pick cell contains an array of processing locations designed to receive containers and an inventory movement tool such as a robotic arm designed to interact with containers received by the pick cell. The pick cells include at least one buffer shelf for processing items.