Automated Picking System Parallel Order Processing
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Solution Overview
Problem
Current automated picking systems face inefficiencies in processing multiple orders simultaneously due to the need to assemble all objects of a single order before processing the next, leading to slow order processing and limited flexibility in adapting to varying order structures and peak performance requirements.
Innovation Solution
The order-picking system employs multiple storage and retrieval devices with guide rails and transport devices that allow for simultaneous removal and transport of objects from multiple storage compartments, using a self-contained guide rail for efficient movement and buffering, enabling quick processing of multiple orders without sequential assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If objects of a single order are assembled on a conveyor belt before processing the next order, then order accuracy is improved, but order processing speed deteriorates
Solution Approach 1:
The system segments the order processing flow by separating object retrieval (performed by stacker cranes) from object transport (performed by conveyor belts). Multiple stacker cranes can retrieve objects for different orders simultaneously, and conveyor belts transport objects from different orders in parallel, eliminating the sequential bottleneck while maintaining order accuracy through dedicated transport paths.
Solution Approach 2:
The conveyor belts operate continuously to transport objects from multiple storage locations to different destinations simultaneously. While one conveyor belt is transporting objects for order A, another conveyor belt can simultaneously transport objects for order B, ensuring continuous productive action without idle waiting time between orders.
2Productivity
If multiple stacker cranes are used for retrieving objects, then retrieval capacity is improved, but parallel retrieval from different orders still cannot be achieved, deteriorating overall system throughput
Solution Approach 1:
The system adds a spatial dimension to parallel processing by introducing multiple conveyor belts operating on different paths and levels. While stacker cranes operate vertically to retrieve objects from storage racks, conveyor belts operate horizontally on multiple levels and routes, creating a three-dimensional transport network that enables simultaneous processing of multiple orders without interference.
Solution Approach 2:
Conveyor belts serve as intermediary transport devices between the stacker cranes and the final destinations. Multiple stacker cranes can deposit objects onto different conveyor belts or the same conveyor belt at different locations, allowing parallel retrieval operations to be coordinated through the intermediary conveyor system without direct conflict between cranes.
3Productivity
If the system is designed for high retrieval throughput to handle peak performance requirements, then order processing speed is improved, but flexibility in adapting to varying order structures deteriorates
Solution Approach 1:
The system employs dynamic control of conveyor belt speeds, directions, and routing to adapt to varying order structures. Conveyor belts can adjust their operation in real-time based on the current order mix, prioritizing high-throughput paths for standard orders while flexibly rerouting for special cases, maintaining both speed and adaptability.
Solution Approach 2:
The conveyor belt system is designed with universal capability to handle multiple order types and structures through a single integrated network. The same conveyor infrastructure can process simple single-item orders, complex multi-item orders, and mixed orders simultaneously by dynamically assigning different paths and priorities, eliminating the need for specialized systems for different order types.
Data Source
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Figure 3~4
AI summary
A picking system comprises at least one rack (11, 12) with multiple storage compartments. At least one storage and retrieval machine (21), which is arranged to move parallel to at least one section of the rack (11, 12), is configured to place objects in and retrieve them from the storage compartments. Several storage compartments are configured to be filled by the storage and retrieval machine (21). At least one transport device (31) is configured to remove all objects contained in a storage compartment. To retrieve objects from the picking system (1), at least one object is removed from a storage compartment of the picking system (1) by means of the storage and retrieval machine (21). It is placed in a storage compartment of the picking system (1). A transport device (31) is moved to the storage compartment (121), and the storage compartment (121) is emptied into the transport device (31).The transport device (31) is then moved to an output area (4) and emptied into the output area (4).