Relay Goods Picking Coordination for Mixed Manual-Robot Orders
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Solution Overview
Problem
The logistics and warehousing industry faces challenges in improving picking efficiency due to the unsynchronized information between manual and robot-based picking systems, leading to inefficiencies in both manual picking and goods-to-person modes.
Innovation Solution
A relay-type goods picking system that combines manual and robot-based picking modes through a control system, using carrying robots, manual and robot picking rack areas, and auxiliary pickup tools to classify orders and allocate tasks in a relay manner, allowing for person-to-goods and goods-to-person picking modes to be used sequentially.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual picking mode is used, then hardware costs are reduced, but information synchronization between goods positions and actual inventory is poor
Solution Approach 1:
The patent merges manual picking and robot-based goods-to-person picking into a unified relay-type system. The control system integrates both modes, allowing them to work together on mixed orders. This combination preserves the low hardware cost advantage of manual picking while incorporating the information synchronization capabilities of automated systems through RFID tags, barcode scanners, and central control software that track inventory in real-time across both picking modes.
Solution Approach 2:
The control system is designed to be universal, managing both manual picking tasks and robot-based picking tasks through a single platform. The system can dynamically allocate orders to either manual pickers or robots based on order characteristics, product types, and warehouse conditions. This multi-functionality allows the system to maintain information synchronization while accommodating both low-cost manual operations and automated high-speed operations.
2Productivity
If robot-based goods-to-person picking mode is used, then picking efficiency is improved, but hardware costs increase
Solution Approach 1:
The patent segments the picking system into distinct functional zones: manual picking rack areas for certain product types, robot picking rack areas for other products, and transfer areas where goods move between modes. This segmentation allows the warehouse to deploy robots only for high-volume or time-sensitive orders while using manual picking for less critical items, thereby improving overall efficiency without requiring complete automation of the entire warehouse.
Solution Approach 2:
Instead of fully automating the entire picking process, the system applies partial automation through the relay-type approach where robots handle specific portions of orders (high-priority items, bulk items) while manual pickers handle the remainder. This partial action provides efficiency improvements for critical paths without incurring the full hardware cost burden of complete automation.
3Adaptability or versatility
If separate manual and robot picking systems are used, then each mode can operate independently, but overall picking efficiency for mixed orders is reduced
Solution Approach 1:
The control system acts as an intermediary that coordinates between independent manual and robot picking systems. When a mixed order is received, the control system analyzes the order contents and splits it into sub-orders, assigning appropriate items to manual pickers or robots. The system manages the handoff process, ensuring that goods picked by one mode are transferred to the appropriate shipping area by the other mode, thereby maintaining operational independence while achieving high overall efficiency.
Solution Approach 2:
The relay-type picking system is dynamic, allowing the allocation of picking tasks between manual and automated modes to change based on real-time conditions. The control system can adjust the proportion of orders assigned to each mode based on order volume, product characteristics, picker availability, and robot performance. This dynamic allocation optimizes overall picking efficiency while preserving the adaptability and operational independence of each picking mode.
Data Source
AI summary
Provided is a relay goods picking system, the system includes: a plurality of carrying robots, a manual picking rack area, auxiliary pickup tools for manual goods picking which store goods for manual picking, a robot picking rack area provided with a plurality of racks used for storing goods and being carried by the plurality of carrying robots, operating positions and a control system capable of communicating with the plurality of carrying robots and manual picking persons. For a mixed order which involves both goods in the manual picking rack area and goods in the robot picking rack area, under control of the control system, a person-to-goods picking mode and a goods-to-person picking mode are used in series to complete the goods picking in a relay manner.