Touchless Pick-and-Put Confirmation Using Gesture Sensing
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Solution Overview
Problem
Existing order picking systems in distribution centers suffer from decreased throughput due to 'button fatigue' and physical interaction requirements, which increase operation time and reduce productivity.
Innovation Solution
A touchless confirmation system using sensors to recognize gestures for confirming operations, eliminating the need for physical button presses, and integrating with a workflow control system to enhance productivity and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical confirmation devices (buttons) are used for operation confirmation, then system reliability is maintained through explicit operator input, but operator fatigue increases and throughput decreases due to repeated physical interactions
Solution Approach 1:
The patent replaces the mechanical button-pressing system with an optical sensing system. The optical sensor detects gestures (hand movements, waves, or other motions) performed by the operator within a defined detection zone, converting mechanical actions into optical signals for confirmation. This substitution eliminates repetitive mechanical interactions while maintaining reliable operation confirmation.
Solution Approach 2:
The patent introduces an optical sensor as an intermediary between the operator and the confirmation system. Instead of direct mechanical contact with a button, the operator performs gestures in the sensor's detection zone, and the optical sensor acts as a mediator to capture and translate these gestures into confirmation signals. This intermediary enables touchless confirmation while maintaining system reliability.
2Ease of operation
If physical confirmation buttons are used throughout the picking area, then operation confirmation is straightforward, but device wear increases and maintenance requirements increase
Solution Approach 1:
The patent replaces mechanical confirmation buttons with optical sensors that have no moving parts and require no physical contact. The optical sensor detects gestures through light reflection or interruption, eliminating wear mechanisms that affect mechanical buttons. This substitution significantly improves device durability while maintaining ease of operation through simple gesture-based interaction.
3Ease of operation
If physical confirmation devices are used in clean or sterile environments, then operator interaction is direct, but contamination risk increases to products
Solution Approach 1:
The patent substitutes mechanical button interaction with optical gesture detection that requires no physical contact with the confirmation device. Operators perform gestures (such as hand waves or movements) within the sensor's detection zone, eliminating the risk of contaminating clean or sterile products while maintaining direct operator interaction through intuitive gesture-based confirmation.
4Reliability
If operators frequently press confirmation buttons, then operation completion is clearly indicated, but button fatigue sets in reducing efficiency
Solution Approach 1:
The patent replaces the mechanical button-pressing action with optical gesture detection. Operators use hand gestures (such as waving or moving the hand through the detection zone) to confirm operations, which is less physically demanding than repeated button pressing. This substitution maintains clear operation completion indication while significantly reducing button fatigue and improving operator comfort during extended periods of use.
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
The system increases throughput by reducing operation times and minimizing operator fatigue, while maintaining system integrity and preventing contamination in clean environments.
Implementation Method 1
an optical sensor configured to recognize a gesture performed by an operator
Data Source
AI summary
A confirmation system including a touchless sensor and method for confirming that an order fulfilment operation has been performed. The system includes at least one touchless sensor to sense or recognize a gesture given by an operator, wherein the gesture confirms that a desired operation has been performed. The touchless sensor is connected to a workflow control system configured to transmit order fulfilment information to and from the touchless sensor. The touchless sensor is configurable to recognize a plurality of gestures, and may be configured to recognize those gestures at a plurality of distances away from the touchless sensor. The touchless system is configurable to provide alerts to operators to indicate locations requiring action. The confirmation system may be provided with a cubby or bin order fulfilment system. Additional features include placement or retrieval sensors, cubby illumination lights, pick-to and put-to lights, and information scanners.