Semicircular Bin Tower Layout for Direct Robotic Item Picking
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Solution Overview
Problem
Conventional automated storage and retrieval systems (AS/RS) are inefficient in processing a large number of objects, requiring significant time and resources to move totes and process items, as they primarily focus on storage and retrieval rather than processing, leading to a need for a more efficient and cost-effective system that assists in processing a wide variety of objects.
Innovation Solution
A storage, retrieval, and processing system featuring a programmable motion device with an end effector that can grasp and move objects within a circular arrangement of bins, allowing for the picking and placement of individual items directly into destination containers, reducing the need for re-sorting and increasing processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional AS/RS use totes that are brought to people for item picking, then the system achieves automated storage and retrieval, but the time and resources required to move totes and process items increases significantly
Solution Approach 1:
The system divides the tote into individual item-level storage locations within a single bin, allowing the robotic system to access and retrieve individual items rather than moving entire totes. This segmentation enables selective item retrieval without the overhead of moving complete tote units, directly reducing the time and resources required for processing.
Solution Approach 2:
The robotic system with articulated arm and end effector autonomously performs item picking, sorting, and placement operations without human intervention. The system self-manages the entire process from bin selection to item placement in destination containers, eliminating the need for human workers to manually handle totes and items, thereby reducing processing time while maintaining high automation.
2Ease of operation
If conventional AS/RS bring totes to people for item picking, then any automated transport system can efficiently move totes, but the person must stand in one place which limits processing speed when handling large numbers of totes
Solution Approach 1:
Instead of bringing totes to a stationary person for picking, the system inverts the approach by bringing the robotic picking mechanism to the bins and performing operations at the storage location. The articulated arm robot moves to each bin, picks items, and places them in destination containers, reversing the traditional flow and enabling high-speed automated processing without human movement constraints.
Solution Approach 2:
The system replaces the human mechanical picking process with an automated robotic system featuring an articulated arm and end effector. This mechanical substitution enables the system to process large numbers of items at high speed without the limitations of human standing position or fatigue, dramatically increasing productivity while maintaining ease of operation through automated control.
3Extent of automation
If conventional AS/RS separate storage and processing jobs, then automated transport can focus on moving totes, but no processing of items occurs within the storage system
Solution Approach 1:
The robotic system with articulated arm and interchangeable end effectors serves multiple functions: it retrieves items from bins, sorts them by destination, places items in destination containers, and can adapt to handle different types of objects. This multi-functional capability integrates storage, retrieval, sorting, and processing operations within a single system, enhancing versatility while maintaining automated operation.
Solution Approach 2:
The system merges previously separate functions (storage management, item retrieval, sorting, and processing) into a single integrated robotic system. The articulated arm robot combines retrieval and sorting operations in one workflow, and the system integrates destination container management with the picking process, eliminating the need for separate processing stages and enabling handling of diverse objects within the storage system itself.
Data Source
AI summary
A storage, retrieval and processing system is disclosed for processing objects. The system includes a plurality of bins including objects to be distributed by the processing system, said plurality of bins being provided in at least a partially generally circular arrangement, a programmable motion device that includes an end effector for grasping and moving any of the objects, said programmable motion device being capable of reaching any of the objects within the plurality of bins, and a plurality of destination containers for receiving any of the objects from the plurality of bins, said plurality of destination containers being provided in a region that is generally within the at least partially generally circular arrangement of the plurality of bins.