Robotic Multi-Line Picking With Mobile Storage Unit Flow
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Solution Overview
Problem
Existing warehouse fulfillment systems are inefficient due to human errors, resource wastage, and space requirements, as they rely on human pickers and require significant space for shelving units, leading to slow and inaccurate order fulfillment.
Innovation Solution
A robotic arm picking system that uses software, firmware, and hardware to transport mobile storage units and cartons, instruct the robotic arm to pick items, and automate the picking process, reducing human intervention and optimizing space usage through automated guided vehicles and conveyors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If human pickers are used to fulfill orders, then flexibility and adaptability are maintained, but error rates increase and task completion time increases
Solution Approach 1:
The patent replaces human mechanical picking operations with an automated robotic arm system. The robotic arm, controlled by a processor, performs item retrieval and placement operations that were previously done manually, thereby eliminating human error while maintaining operational flexibility through programmable control.
Solution Approach 2:
The system enables automated self-service picking where the robotic arm autonomously retrieves items from storage units and places them in cartons without human intervention. The processor coordinates the entire picking process, allowing the system to serve itself in completing order fulfillment tasks.
2Ease of operation
If entire shelving units are transported to human pickers, then items are made accessible, but significant space and resources are consumed
Solution Approach 1:
The patent divides the storage system into individual mobile storage units that can be independently transported by automated guided vehicles. Instead of moving entire shelving units, only the specific storage units containing needed items are brought to the picking station, reducing space requirements while maintaining item accessibility.
Solution Approach 2:
The system introduces mobile storage units that operate in a different spatial dimension - they are transported on rails or guides to positioning stations where the robotic arm accesses items. This dimensional reorganization allows compact storage density while maintaining quick access to individual units without requiring large open warehouse spaces.
3Productivity
If mobile storage units are transported by automated guided vehicles, then continuous item stream is maintained, but system complexity increases
Solution Approach 1:
The automated guided vehicles serve multiple functions: they transport mobile storage units from storage areas to positioning stations, return empty units to storage, and coordinate with the robotic arm operations. This multi-functionality reduces the need for separate specialized equipment for each operation, managing system complexity while maintaining continuous item flow.
Solution Approach 2:
The system incorporates feedback mechanisms where the processor monitors the positions and statuses of mobile storage units and cartons, dynamically coordinating AGV movements and robotic arm operations. This feedback control ensures continuous item flow while optimizing system resource utilization and managing complexity through intelligent coordination.
4Productivity
If robotic arm performs automated picking, then labor costs are reduced, but initial system investment increases
Solution Approach 1:
The robotic arm system is designed with dynamic capabilities including programmable motion control, adjustable gripping forces, and flexible positioning. The processor enables the system to adapt to different item types, carton sizes, and picking patterns, providing long-term operational flexibility that justifies the initial investment through sustained productivity gains.
Solution Approach 2:
The system utilizes parameter changes in the robotic arm's operation - varying speed, position, grip force, and motion trajectories - to optimize picking efficiency for different items. The processor dynamically adjusts these parameters based on item characteristics and order requirements, maximizing operational efficiency to offset the initial system cost.
Data Source
AI summary
A system may transport a first set of mobile storage units from a storage area to an active picking bay of a robotic picking station, the robotic picking station including a robotic arm, the active picking bay being within a range of motion of the robotic arm. A system may transport a carton to the robotic picking station, for example, using one or more conveyors. A system may instruct the robotic arm to move a first item from the first set of mobile storage units into the carton. A system may transport the carton out of the robotic picking station.