Mobile Robot Tote-Array Putaway With Dynamic Route Recalculation
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Solution Overview
Problem
Warehouse stocking and putaway operations are labor-intensive and inefficient, especially when items are mixed together, requiring extensive travel and inefficient routing of human workers, which can delay the fulfillment process and reduce efficiency in shipping items.
Innovation Solution
A robotic dynamic putaway selection system using a mobile robot with a tote-array that allows cooperative robot-operator interaction to optimize routing and minimize upfront effort, where the robot determines an optimal route for putting away items without presorting, using data from a warehouse management server and order-server, and recalculates routes dynamically as items are placed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human operators manually sort and place items in the warehouse, then items can be stored in storage bins, but extensive travel and inefficient routing occur, reducing fulfillment efficiency
Solution Approach 1:
The patent replaces human operators with mobile robots equipped with scanners and navigation systems to perform item sorting and placement operations. The robotic system uses automated routing algorithms to determine optimal paths between storage bins, eliminating the inefficiencies of manual travel and routing while maintaining the ability to sort and place items accurately.
Solution Approach 2:
The system performs preliminary routing calculations and item assignments before the actual putaway operation begins. The central control system pre-determines the optimal sequence of locations and assigns specific items to specific storage bins in advance, allowing operators or robots to follow predetermined efficient paths without making decisions during traversal.
2Ease of operation
If a dedicated group of operators sorts and scans items before stocking, then items can be organized for later picking, but this draws workers away from picking tasks and remains inefficient
Solution Approach 1:
The mobile robots are designed to perform multiple functions: they can conduct putaway operations by transporting and placing items in storage bins, and they can also assist with picking operations by delivering items to packing stations. This multi-functionality eliminates the need for dedicated operators solely for sorting and stocking, as the same robotic units can switch between putaway and picking support tasks.
Solution Approach 2:
The robotic system performs its own routing optimization and navigation without requiring human operators to make routing decisions. The central control system automatically manages the robots' schedules, assigns tasks, and recalculates routes in real-time based on current warehouse conditions, allowing the system to serve itself rather than requiring dedicated human management for each operation.
3Productivity
If items are placed in storage bins without presorting, then routing can be optimized, but dynamic routing recalculation is required as items are placed
Solution Approach 1:
The routing system is designed to be dynamic rather than static. As robots place items in storage bins and complete tasks, the central control system continuously monitors progress and recalculates routes in real-time to optimize the remaining putaway sequence. This dynamic adaptation allows the system to maintain optimal efficiency throughout the entire putaway process rather than following a fixed predetermined path that becomes suboptimal as items are placed.
Solution Approach 2:
The system incorporates continuous feedback loops where the central control system receives real-time data from robots about item placement completion, current location, and remaining tasks. Based on this feedback, the system dynamically adjusts routing instructions and task assignments to maintain optimal efficiency. The feedback mechanism enables the routing algorithm to adapt to changing conditions without requiring complete re-planning.
Data Source
AI summary
Processes are provided for dynamically sorting and storing items in a warehouse without the need for presorting items and without delaying or negatively impacting the efficiency of operators in the warehouse. Items are individually scanned and placed in totes of a tote-array provided on a mobile robot. An optimized route is calculated based on the items in the tote-array, and the robot navigates to a first location on the route. When the item has been put away, a replacement item is placed in the just-emptied tote of the tote-array, and an updated route is calculated. A robot capable of navigating to predefined locations for storing items is a warehouse is provided.