Robotic Picking Cell for Warehouse Order Fulfillment

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Solution Overview

Problem

Current order fulfillment processes are inefficient, leading to delays and human errors, which can alienate customers and increase costs, as they struggle to meet high expectations for timely deliveries and accurate order processing.

Innovation Solution

The implementation of a dense inventory storage system with robotically-movable mobile storage units, automated order assemblage systems, and a control system that includes mobile robots and a robotic picking cell to streamline and optimize material flow, enabling efficient transfer of sellable units from storage to outbound containers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual order fulfillment processes are used, then operational flexibility is maintained, but human errors increase and efficiency decreases

Engineering Contradiction:

Improveorder fulfillment accuracyVSAvoidorder fulfillment speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical picking operations with an automated robotic picking system. The robotic picking cell uses automated mechanisms to retrieve items from storage units and place them in outbound containers, eliminating human error while maintaining high-speed operation. The control system coordinates robotic arms and conveyors to fulfill orders automatically, achieving both accuracy and speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service through automated inventory management. The robotic picking cell autonomously identifies required items, retrieves them from appropriate storage units, and assembles complete orders without human intervention. The control system automatically manages the entire fulfillment process from order receipt to packaging, allowing the system to serve itself.

Inventive Principle:

Principle #25Self-service

2Area of stationary object

If traditional warehouse storage systems are used, then ease of access is maintained, but warehouse space requirements increase

Engineering Contradiction:

Improvewarehouse spaceVSAvoidmaterial flow efficiency

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The patent transitions from traditional two-dimensional floor-based storage to three-dimensional vertical storage structures. Mobile storage units are stacked vertically and can be moved along vertical rails, utilizing the vertical dimension of the warehouse space. This dramatically increases storage capacity within the same footprint while maintaining accessibility through automated retrieval systems.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The storage system employs dynamic mobile storage units that can move autonomously along tracks and rails. These units transition between stationary storage positions and mobile transport states, allowing the system to adapt to different operational requirements. The mobile units can be dispatched to picking locations on demand, optimizing both space utilization and material flow efficiency.

Inventive Principle:

Principle #15Dynamics

3Productivity

If automated robotic systems are deployed, then order fulfillment efficiency increases, but system complexity increases

Engineering Contradiction:

Improveorder fulfillment speedVSAvoidautomation system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The automated system is divided into distinct functional modules: mobile storage units, robotic picking cells, conveyance systems, and control systems. Each module operates semi-independently with well-defined interfaces, allowing for easier maintenance, troubleshooting, and scaling. The segmentation enables parallel operation of multiple picking cells and storage units, increasing overall productivity while managing complexity through modularity.

Inventive Principle:

Principle #1Segmentation

4Area of stationary object

If dense inventory storage is implemented, then warehouse space is optimized, but access to individual items becomes more difficult

Engineering Contradiction:

Improvewarehouse space utilizationVSAvoiditem retrieval ease

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The patent introduces mobile robotic units as intermediaries between the dense storage structures and the picking locations. These robotic units navigate through the dense storage array, retrieve specific items using automated grippers or manipulators, and transport them to outbound containers. This intermediary system maintains space efficiency while eliminating the difficulty of manual access to densely packed inventory.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11498765B2Warehousing and order fulfillment systems and methods

Publication Date: 2022.11.15 TARGET BRANDS INC

AI summary

Warehouse automation and methods of controlling material flow can be used to streamline order fulfillment. For example, according to some embodiments described herein, a method includes: causing a first mobile robot to engage with and transport a mobile storage unit to a robotic picking cell, causing a second mobile robot to engage with and transport an outbound container to the robotic picking cell, and causing the picking robot to transfer a sellable unit from the mobile storage unit to the outbound container.