Robotic Product Picking via Virtual Stack Alignment
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Solution Overview
Problem
Current product picking systems in warehouses lack efficiency and accuracy in selecting and arranging products based on specific business rules, leading to potential errors and increased operational costs.
Innovation Solution
A product picking system that includes a work order module, a vision module with sensors, and a processor to generate a 3D virtual stack and operate a robotic arm, ensuring products are selected and arranged according to predefined business rules, including quality inspections and precise stacking instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual product picking is used, then operational flexibility is maintained, but picking efficiency and accuracy deteriorate
Solution Approach 1:
The system enables automatic self-service product picking through autonomous vehicles that navigate warehouse aisles, identify products using vision systems, and execute picking operations without human intervention. The vehicle independently completes the entire picking workflow from receiving instructions to transporting selected products.
Solution Approach 2:
Manual mechanical picking operations are replaced with an automated system combining autonomous navigation, computer vision technology, and robotic manipulation. The mechanical actions of locating, identifying, selecting, and transporting products are performed by automated components rather than human operators.
2Measurement precision
If automated vehicle picking is implemented, then picking accuracy improves, but business rule compliance verification becomes more complex
Solution Approach 1:
Business rules are pre-configured and stored in the system before picking operations begin. The system receives and stores comprehensive picking instructions including product selection criteria, stacking requirements, and quality standards, then automatically applies these pre-established rules during the picking process without requiring complex real-time verification.
Solution Approach 2:
The vision system continuously captures images of products and the autonomous vehicle's actions, comparing them against the pre-configured business rules. The system provides real-time feedback to verify compliance with picking instructions, ensuring accurate product selection and proper stacking while maintaining rule verification through automated comparison rather than complex manual checks.
3Reliability
If quality inspection is performed on each product, then product quality assurance improves, but inspection time increases
Solution Approach 1:
The vision system performs quality inspection continuously throughout the picking process rather than as a separate sequential step. As the vehicle approaches, identifies, and selects products, the vision system simultaneously captures images for quality verification, integrating inspection into the continuous picking workflow and eliminating dedicated inspection time.
Solution Approach 2:
Quality inspection is performed preliminarily during the product identification phase before the actual picking action. The vision system analyzes product images and verifies quality attributes while the vehicle is still navigating to the product location, so that by the time the robotic gripper executes the pick, quality verification is already complete.
Data Source
AI summary
The disclosed embodiments include product picking systems and methods to pick products. In one embodiment, the system includes a work order module configured to receive a work order to obtain at least one product, obtain a virtual stack of the at least one product based on the work order, the virtual stack being a 3D representation of the at least one product, and determine a set of business rules for selecting each product of the at least one product. The system also includes a vision module configured to identify a first product of the at least one product. The system further includes a processor configured to determine whether the first product satisfies business rules for selecting the first product is satisfied, and configured to operate a robotic arm to select the first product and to arrange the first product to form a physical stack corresponding to the virtual stack.