Shipping buffer for an order-picking system
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Solution Overview
Problem
The challenge lies in efficiently managing the picking and shipping of diverse goods in retail stores, where large quantities of single-variety goods need to be broken down into smaller units and recombined, while synchronizing the picking process with transport vehicle readiness, which often leads to traffic blocking or waiting times due to the diversity of carriers and handling difficulties.
Innovation Solution
An order-picking system with a shipping buffer that includes a storage area and a staging area, connected by an automated stacker crane and gravity conveyor, allowing for temporary storage and automated sequencing of goods units, enabling efficient handling and transport of various carriers like pallets and roller containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If goods are picked into goods units too early, then the picking process can be completed in advance, but the goods units must be stored temporarily blocking traffic routes until transport vehicles are ready
Solution Approach 1:
The goods-out area is segmented into multiple lanes, each equipped with its own conveyor system and stacking positions. This allows goods units to be staged in an organized manner along different lanes, preventing traffic blocking by distributing the staging activity across multiple parallel paths rather than a single congested area.
Solution Approach 2:
A buffer zone is introduced between the picking area and the transport vehicle loading area. This buffer zone acts as an intermediary where goods units can be temporarily staged on conveyors and stacking positions without blocking the main traffic routes. The buffer decouples the picking process from the loading process, allowing independent operation of both.
2Object-generated harmful factors
If picking of goods units starts too late, then traffic routes remain clear, but transport vehicles experience unwanted waiting times and downtimes
Solution Approach 1:
Goods units are picked and staged in advance on the conveyor systems and stacking positions in the buffer zone before transport vehicles arrive. This preliminary action ensures that goods are ready and positioned for immediate loading when vehicles arrive, eliminating waiting times and downtimes while maintaining clear traffic routes.
Solution Approach 2:
The conveyor systems operate continuously to transport picked goods units from the picking area through the buffer zone to the loading positions. This continuous operation ensures that goods are constantly being prepared and positioned, maintaining an uninterrupted flow that prevents vehicle waiting times while keeping traffic routes clear of stationary goods.
3Adaptability or versatility
If diverse carriers like pallets and roller containers are used, then various goods can be handled flexibly, but organizing and handling the goods units becomes difficult
Solution Approach 1:
The conveyor system and stacking positions are designed with universal capabilities to handle multiple types of carriers including pallets, roller containers, and other goods unit configurations. The system uses adjustable support structures and standardized conveyor mechanisms that can accommodate different carrier types, maintaining ease of operation despite carrier diversity.
Solution Approach 2:
The system standardizes the interface between different carrier types and the conveyor system by using uniform stacking positions and conveyor belt configurations. This homogenization of the handling interface simplifies operation, as the same basic mechanisms handle all carrier types, reducing operational complexity despite the diversity of goods units being transported.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures seamless issuance of picked goods units independently of collection times, optimizing truck loading and reducing personnel needs in the goods-out area by automating the staging and transport of goods units in a predefined sequence, thus minimizing downtime and traffic issues.
Implementation Method 1
a gravity conveyor (5) for the shipping buffer (3)
Data Source
AI summary
The present invention concerns an order-picking system, comprising a goods-in buffer (3) with at least one storage area (4), in which the picked goods units are stored before they leave the order-picking system, and at least one staging area (6), in which the picked goods units are staged automatically by an operating device in accordance with a predetermined sequence. In addition, the present invention comprise a pallet racking warehouse for a shipping buffer and a stacker crane for a corresponding pallet racking warehouse. A gravity conveyor (5) for the staging area of the shipping buffer is also the subject-matter of the present invention.