Robotic Bin Picking to Reduce Tote Transport in AS/RS
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Solution Overview
Problem
Conventional automated storage and retrieval systems (AS/RS) are limited by the time and resources required to move totes towards and away from individuals, and they do not efficiently process a wide variety of objects, necessitating a more efficient system for storing, retrieving, and processing objects.
Innovation Solution
A storage, retrieval, and processing system that includes a storage bin system, a retrieval conveyance system, a programmable motion device with an end effector, and a destination bin system, which enables direct processing of objects within the system and efficient movement between storage and destination bins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional AS/RS bring totes to people for item picking, then people can efficiently pick items from totes, but the system requires significant time and resources to move totes to and from each person
Solution Approach 1:
Instead of bringing totes to people for item picking, the system inverts the approach by bringing people to the totes. The robotic picking system moves to a stationary tote, picks items directly from it, and places them in destination bins, eliminating the need to transport totes between locations.
Solution Approach 2:
The system uses vision systems and sensors to create digital representations of tote contents, enabling the robotic system to identify and locate items without physical inspection. This allows the robot to plan and execute picking operations efficiently while minimizing movement time.
2Adaptability or versatility
If conventional AS/RS use stationary totes with human pickers, then item selection is flexible, but the system cannot efficiently process a wide variety of objects
Solution Approach 1:
The robotic picking system is designed to be dynamic and adaptable, capable of adjusting its picking strategy based on the type of objects in the tote. The system can handle a wide variety of object shapes, sizes, and fragilities by modifying its end effector and picking motions in real-time.
Solution Approach 2:
The system changes operational parameters such as gripper force, picking speed, and trajectory based on the detected object properties. This allows the same robotic system to efficiently process diverse objects by dynamically adjusting its parameters rather than requiring different equipment for each object type.
3Adaptability or versatility
If people manually process items from totes, then complex processing tasks can be performed, but the system requires significant human intervention and resources
Solution Approach 1:
The robotic system performs processing tasks autonomously without human intervention. The robot can identify items, determine their destination, execute picking operations, and place items in appropriate bins all independently, eliminating the need for human workers to manually process each item.
Solution Approach 2:
The system replaces human manual processing with automated robotic mechanisms. The robotic arm with programmable end effectors substitutes human hands, while vision systems and sensors replace human perception, enabling automated decision-making and execution of processing tasks.
4Ease of manufacture
If conventional systems separate transport and processing functions, then each component can be optimized independently, but the overall system efficiency is limited by the need to move totes between locations
Solution Approach 1:
The system merges the transport and processing functions into a single integrated operation. The robotic arm moves to the tote, performs picking operations, and returns to the destination bin in one continuous cycle, eliminating the separate steps of transporting totes to workers and then returning them.
Data Source
AI summary
A storage, retrieval and processing system for processing objects is disclosed. The storage, retrieval and processing system includes a storage bin system for receiving at a first end thereof, a plurality of storage bins providing storage of a plurality of objects, a retrieval conveyance system at a second end of the storage bin system that is generally opposite the first end of the storage bin system, where the retrieval conveyance system is in communication with the plurality of storage bins, a programmable motion device in communication with the retrieval conveyance system for receiving the storage bins from the plurality of storage bins, where the programmable motion device includes an end effector for grasping and moving a selected object out of a selected storage bin, and a destination bin system for receiving the selected object from the end effector of the programmable motion device at first end of the destination bin system, and the destination bin system provides access to the plurality of destination bins at a second end thereof that is generally opposite the first end of the destination bin system.