Picker AGV Fulfillment for High-Density Warehouse Picking
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Solution Overview
Problem
Current inventory management and movement systems in warehouses face inefficiencies, particularly in terms of volumetric utilization and cost-per-order, as they are limited by ergonomic work heights and high-throughput requirements, leading to the need for improved systems that can maximize warehouse space and minimize operational costs.
Innovation Solution
The implementation of a Picker Automated Vehicle (PAV) system that automates the movement of human pickers on AGVs to inventory stock bins, allowing for efficient retrieval and placement of items in shipping containers based on customer orders, utilizing tote-moving modular assemblies and a sophisticated software system to optimize paths and minimize time per pick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If human pickers are placed at fixed locations with robots moving containers to them (goods-to-picker method), then automation level increases, but volumetric utilization of warehouse space decreases and device complexity increases
Solution Approach 1:
The patent inverts the conventional goods-to-picker approach by implementing a picker-to-goods system where the human picker moves with the automated vehicle to the inventory containers. This reversal allows the picker to access inventory at various heights and locations without requiring fixed pick stations, thereby improving volumetric utilization of warehouse space while maintaining high automation levels through the autonomous vehicle navigation and container handling systems
Solution Approach 2:
The patent utilizes vertical space by enabling the automated vehicle to access inventory containers at multiple heights, including elevated positions that were previously inaccessible to ground-based fixed pickers. The vehicle's ability to operate in three-dimensional space, accessing containers at different elevations and positions, dramatically increases the volumetric utilization of warehouse space compared to traditional two-dimensional floor-based picking systems
2Extent of automation
If fixed location picking with robot-delivered containers is used, then automation increases, but the number of personnel required increases due to multiple fixed pick stations
Solution Approach 1:
The automated vehicle serves multiple functions: it transports the human picker to various inventory locations, provides elevated access to containers, performs picking operations, and returns to base. This single multi-functional mobile unit replaces the need for multiple fixed pick stations, each requiring separate robot systems, thereby reducing overall device complexity while maintaining high automation levels
Solution Approach 2:
The system transitions from static fixed pick stations to a dynamic mobile picking platform. The automated vehicle can dynamically reposition the picker to any inventory location as needed, providing flexibility and adaptability that eliminates the need for multiple fixed infrastructure elements. This dynamic approach reduces device complexity by consolidating multiple fixed functions into a single mobile system
3Productivity
If conventional goods-to-picker systems are implemented, then inventory can be accessed, but volumetric utilization is limited by ergonomic work heights
Solution Approach 1:
The patent extends inventory access into the vertical dimension by enabling the automated vehicle to reach and access containers at elevated heights that exceed ergonomic work limits for ground-based pickers. The vehicle's lifting and positioning capabilities allow access to three-dimensional storage spaces, dramatically increasing volumetric utilization from the limited horizontal plane access of conventional systems to comprehensive spatial access including vertical volumes
Data Source
AI summary
A method and apparatus of moving a picker on an automatically guided vehicle (AGV) along with a plurality of totes to a successive plurality of inventory stock bins to allow the picker to successively retrieve each of a plurality of stock items from the stock bins and place the respective items in a preselected one of the plurality of totes based on a customer order. In some embodiments, the picker is a human picker. In some embodiments, the totes are shipping containers.