Transformable Mobile Units for Dynamic Slotting
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Solution Overview
Problem
Current pick/put systems in warehouses face inefficiencies due to the need for relocating items during slotting, which increases handling costs and reduces order fulfillment rates, and are limited by scalability and fault tolerance issues in existing technologies.
Innovation Solution
A reconfigurable light-directed pick/put system using transformable mobile units that can dynamically change between mobile and stationary configurations, supported by audio and visual indicators, allowing for efficient slotting and reduced product handling without relocating items, and enabling dynamic slotting and put wall configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If items are relocated during slotting in traditional pick/put systems, then storage optimization can be achieved, but handling costs increase and order fulfillment rates decrease
Solution Approach 1:
The system dynamically transforms mobile units between mobile and stationary configurations based on operational needs. During picking operations, units remain mobile for rapid deployment. During slotting operations, units transform to stationary configuration to serve as stable storage locations, eliminating the need to relocate items between different storage areas while still achieving storage optimization.
Solution Approach 2:
Mobile units serve multiple functions: they act as mobile storage during transport, transform into stationary storage during slotting operations, and can serve as picking stations. This multi-functionality allows the same physical units to adapt to different operational modes without requiring separate dedicated infrastructure for each function.
2Ease of operation
If traditional light systems are hard-wired to individual containers, then light indication can be provided, but system scalability is limited and fault tolerance is poor
Solution Approach 1:
The patent replaces hard-wired mechanical electrical connections with wireless communication technology. Each mobile unit and stationary unit is equipped with wireless transceivers that communicate picking instructions and status information without physical wiring. This substitution enables easy addition of new units to the system without requiring complex wiring infrastructure, dramatically improving scalability.
Solution Approach 2:
The system introduces wireless communication as an intermediary between control systems and storage units. Instead of direct electrical wiring, wireless signals mediate the transmission of light indication commands and status data, allowing units to be added, removed, or reconfigured without physical connection changes.
3Extent of automation
If a central computer controls the entire pick/put system, then centralized coordination is achieved, but fault tolerance is poor as single point of failure causes complete system failure
Solution Approach 1:
The system segments the centralized control architecture into distributed intelligent units. Each mobile unit and stationary unit contains its own controller with local decision-making capabilities. Units can autonomously coordinate with nearby units and maintain operational independence, allowing the system to continue functioning even if individual units or communication links fail.
Solution Approach 2:
The system changes the control architecture parameter from centralized to distributed. Instead of a single central computer making all decisions, control parameters and decision-making authority are distributed across multiple autonomous units, each capable of independent operation and local coordination.
4Adaptability or versatility
If mobile units frequently transform between mobile and stationary configurations, then dynamic slotting capability is improved, but operational longevity decreases due to wear on moving parts
Solution Approach 1:
The patent replaces mechanical transformation mechanisms with magnetic field-based configuration changes. Mobile units use electromagnetic actuators to adjust shelving positions and container placements without mechanical moving parts. This substitution eliminates wear from friction and mechanical contact, dramatically extending operational longevity while maintaining dynamic reconfiguration capability.
Data Source
AI summary
This invention is a dynamically reconfigurable pick-put system comprising: a digitally transformable mobile unit having a mobile unit computer and a mobile unit light bar controller, with a set of transformable mobile unit computer readable instructions included with the digitally transformable mobile unit that can digitally transform the mobile unit from a mobile unit configuration to a stationary unit configuration and can (a) direct a user to a particular stationary unit, actuate the mobile unit light bar to identify a location on the digitally transformable mobile unit where the item picked from the stationary unit is to be placed on the digitally transformable mobile unit, when in the mobile unit configuration, and (b) actuate the mobile unit light bar to identify the location of an item on the digitally transformable mobile unit to be picked when in the stationary unit configuration.