Proximity-Guided Picking Cart for Faster Warehouse Order Fulfillment
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Solution Overview
Problem
The increasing complexity of product types and delivery schemes in remote order fulfillment systems, particularly in large-order customer companies, leads to inefficiencies in product picking, packing, and delivery, with a heightened risk of loss and operational inconvenience.
Innovation Solution
A method and apparatus utilizing proximity sensors to guide a cart equipped with picking boxes to specific regions where users are located, allowing users to efficiently pick products by providing information on the current and next picking targets, and enabling automatic movement based on proximity detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of products and delivery schemes increases to meet diverse customer needs, then the adaptability of the system improves, but the complexity of picking and packing operations increases
Solution Approach 1:
The system divides the warehouse into multiple picking regions with specific product categories, and further segments the picking process into automated cart navigation and manual product selection. This segmentation allows the system to handle diverse product types efficiently while keeping individual picking tasks simple and manageable.
2Adaptability or versatility
If manual product picking is performed in a large warehouse with many product types, then the system can handle diverse orders, but the time required to find and pick products increases
Solution Approach 1:
The system pre-calculates and determines the optimal picking path and region before the picking operation begins. The automated cart navigates to the predetermined region based on the order requirements, eliminating the time-consuming process of searching for products during the actual picking operation.
Solution Approach 2:
The automated picking cart autonomously navigates to the correct regions and positions itself for product picking without human intervention. The system self-manages the navigation and positioning tasks, allowing pickers to focus solely on the quick task of selecting products from pre-positioned locations.
3Productivity
If automated cart movement is implemented to reduce picking time, then the productivity improves, but the risk of collision with users and loss of products increases
Solution Approach 1:
The automated cart system dynamically adjusts its movement based on real-time proximity detection. When a user is detected within a predetermined distance, the cart automatically stops or slows down, preventing collisions. This dynamic response ensures safety while maintaining high productivity during normal operation.
Solution Approach 2:
The proximity sensor continuously provides feedback about user presence to the cart control system. This feedback loop enables the cart to make real-time decisions about its movement, stopping when users are nearby and resuming when the path is clear, thus balancing speed and safety.
4Adaptability or versatility
If the warehouse space is loaded with many types of products to meet diverse orders, then the system versatility improves, but the difficulty of efficiently finding and picking products increases
Solution Approach 1:
The warehouse is segmented into multiple picking regions, each dedicated to specific product categories or types. This spatial segmentation allows the system to efficiently locate products by directing the cart to the appropriate region based on the order requirements, eliminating the need to search through the entire warehouse.
Solution Approach 2:
The automated picking cart acts as an intermediary between the order system and the products. It receives picking information, autonomously navigates to the correct regions, and positions itself for efficient product collection. This intermediary function simplifies the picking process by handling navigation and positioning tasks automatically.
Data Source
AI summary
A method for assisting proximity sensor-based product picking, comprises: deriving a product to be currently picked from a picking product list; selecting a first user terminal positioned in a first region where the product to be currently picked is displayed; moving a cart including a plurality of picking boxes within a certain distance from the first user terminal; when the cart is positioned within the certain distance from the first user terminal, stopping movement of the cart; providing information about the product to be currently picked to the first user terminal; and when picking completion information is received from the first user terminal, deriving a product to be picked next from the picking product list, wherein a distance between the cart and the first user terminal is determined on the basis of a proximity sensor.