Robotic Put Wall With Removable Intermediate Holders
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Solution Overview
Problem
Existing order fulfillment systems in distribution centers, particularly those using piece picking, face inefficiencies and human errors due to the complexity of directing operators to pick and put products from multiple donor and order containers, even with pick-to-light or pick-to-voice systems.
Innovation Solution
A material handling system incorporating a put wall with multiple storage locations accessible from both sides, equipped with robotic arms and a controller communicating with inventory data, which automatically directs the robotic arms to engage and move removable intermediate holders containing articles to empty order containers, enhancing efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pick-to-light or pick-to-voice systems are used to direct operators, then efficiency of human operator is improved, but human error remains due to repetitious tasks
Solution Approach 1:
The patent replaces the human operator's manual picking and sorting actions with an automated robotic system. The robotic arm performs the mechanical picking, transfer, and placement of articles, eliminating human error while maintaining high efficiency. The system uses vision guidance and automated control to replicate and enhance the capabilities of pick-to-light systems without human intervention.
Solution Approach 2:
The robotic system operates autonomously to perform the picking and sorting tasks. The controller automatically directs the robotic arm based on order requirements, and the system self-manages the entire fulfillment process from picking to placement in order containers without requiring human operators to perform repetitious manual tasks.
2Adaptability or versatility
If multiple donor containers and order containers are used to fulfill orders, then order fulfillment capability is improved, but system complexity increases
Solution Approach 1:
The robotic arm serves multiple functions: it can pick from any donor container, transfer articles, and place them in any order container. The system is designed to handle multiple container types and configurations, making it universally applicable to various order fulfillment scenarios while managing complexity through centralized automated control.
Solution Approach 2:
The robotic arm acts as an intermediary between donor containers and order containers. It mediates the transfer process, managing the complexity of multiple container interactions through a single controlled mechanism. The controller serves as another intermediary, coordinating the complex logistics of which articles move from which containers to which destination containers.
3Productivity
If automated robotic arms are deployed to service put wall, then productivity and accuracy are improved, but device complexity increases
Solution Approach 1:
The robotic system is segmented into modular components: the robotic arm, end effector, controller, and vision system. Each component performs a specific function and can be independently controlled or replaced. This segmentation manages complexity by breaking down the automated picking system into manageable modules while maintaining high productivity through their coordinated operation.
Data Source
AI summary
A material handling system automatically each picking orders using a put wall. A controller determines whether any of more than one removable intermediate holders in a put wall that are within the reach of a first robotic arm contain one or more articles that are ready for transporting away from the put wall. The controller directs the first robotic arm to: (i) engage the selected removable intermediate holder, (ii) move the selected removable intermediate holder to an empty order container, and (iii) reorient the selected removable intermediate holder to transfer the one or more articles from the selected removable intermediate holder to the empty order container. In one or more embodiments, the articles can be placed in the put wall by conveying donor totes to an each picking robotic arm that places picked articles into an end effector of a second robotic arm.