Automated Sorting Robots for Warehouse Picking Efficiency
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Solution Overview
Problem
Existing warehouse sorting and picking methods are inefficient, require significant space, and often result in errors, especially when handling fragile items or high-demand items like pharmacy products, due to manual handling and slow re-stacking processes in systems like rack warehouses and ABC/chaotic storage systems.
Innovation Solution
A method utilizing robots with gripping and optical units for precise and gentle item handling, combined with conveyor technology and data processing for error-free sorting and picking, allowing for simultaneous access to multiple storage containers and target containers, enabling efficient and space-saving operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual stocking of shelf storage systems is used, then employees can access and stock items, but the process is continuous and time-consuming requiring significant space
Solution Approach 1:
The system uses robots equipped with gripping units that autonomously sort and pick items from storage containers without requiring manual stocking. The robots present storage containers to presentation tables and transfer items automatically, making the system self-sufficient and eliminating continuous manual intervention.
Solution Approach 2:
Manual mechanical stocking operations are replaced with automated robotic systems. The robots use gripping units to handle items and present storage containers to presentation tables, substituting human labor with automated mechanical systems that operate continuously at high speed.
2Volume of stationary object
If storage containers are stacked according to chaotic principle, then high volume utilization is achieved, but robots must move containers above the desired one which is time-consuming
Solution Approach 1:
Storage containers are pre-presented on presentation tables before being needed for sorting or picking operations. The system proactively prepares containers by bringing them to accessible locations in advance, eliminating the time-consuming process of moving stacked containers during operations.
Solution Approach 2:
The storage system is divided into multiple presentation tables that can be independently accessed. Instead of a single stacked structure where containers block access to others, the system segments storage into multiple accessible surfaces, allowing parallel access to multiple containers simultaneously.
3Reliability
If employees perform visual inspection during picking, then accuracy can be maintained, but the process is slow and requires monotonous manual task with risk of human error
Solution Approach 1:
Manual visual inspection by employees is replaced with optical units equipped on the robots. These optical units automatically capture images of items and compare them against the picking list, providing verification without requiring human attention and enabling continuous high-speed operation without fatigue or error.
4Ease of operation
If robots restack storage containers in ABC principle system, then frequently requested containers are at top, but the restacking process itself is time-consuming
Solution Approach 1:
The system autonomously manages container positioning without requiring centralized restacking operations. Robots independently handle container presentation and positioning based on real-time picking requirements, eliminating the need for periodic system-wide restacking while maintaining optimal accessibility.
Data Source
Figure 1
AI summary
The invention relates to a device for sorting articles, wherein the device is configured in a first operating mode to sort mixed and single-type articles from at least one storage container into at least one target container; and in a second operating mode to pick articles from at least one sorted storage container into at least one target container according to a predetermined picking list. The invention further relates to a method for sorting and picking articles, comprising the process steps I. Sorting articles from at least one storage container into at least one sorted target container; and/or II. Picking articles from at least one storage container into at least one target container according to a predetermined picking list; wherein process step I. or II. is carried out as required.The device and method according to the invention are characterized by high efficiency and speed.