Warehouse Order Splitting to Avoid Robot Picking Conflicts
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Solution Overview
Problem
Existing warehouse management systems face inefficiencies due to conflicts between shelf handling robots and tote handling robots, leading to queuing and reduced productivity as they often target the same inventory, necessitating improved management strategies.
Innovation Solution
A warehouse management system and method that splits order tasks into sub-orders and dispatches them to separate workstations, utilizing a control server to coordinate shelf handling robots and tote handling robots to transport inventory receptacles between storage areas, thereby avoiding conflicts and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual tracking and paper-based record keeping are used, then implementation cost is low, but productivity and accuracy of inventory management deteriorate
Solution Approach 1:
The patent replaces manual mechanical tracking methods with an automated electronic system using RFID tags, readers, and a centralized server. This substitution eliminates paper-based record keeping and manual inventory tracking, directly improving productivity while the modular architecture keeps implementation costs manageable through phased deployment options.
Solution Approach 2:
The system enables self-service inventory management where the RFID tags automatically transmit their own identification and tracking information to readers without requiring manual data entry. The server automatically processes and stores inventory data, reducing the need for manual intervention and improving operational efficiency.
2Measurement precision
If automated RFID tracking system is implemented, then productivity and accuracy improve, but device complexity and implementation cost increase
Solution Approach 1:
The RFID tags serve multiple functions simultaneously: they provide unique identification, track inventory location, monitor item status, and enable real-time data collection. This multi-functionality reduces the need for separate tracking devices and systems, managing complexity while improving accuracy.
Solution Approach 2:
The centralized server acts as an intermediary that receives data from multiple RFID readers, processes the information, and manages the database. This intermediary layer simplifies the overall system architecture by centralizing complex data processing tasks and providing a unified interface for inventory management.
3Reliability
If comprehensive inventory tracking is implemented, then loss prevention improves, but device complexity increases
Solution Approach 1:
The system provides continuous real-time tracking of inventory items as they move through the warehouse. RFID readers continuously scan and update the server with item locations and status, ensuring uninterrupted monitoring that improves reliability without requiring complex periodic manual checks.
Solution Approach 2:
The system implements feedback mechanisms where the server continuously monitors inventory data from RFID tags and can trigger alerts or notifications when items are misplaced, stolen, or require attention. This automated feedback loop improves reliability by immediately detecting and reporting issues without manual intervention.
Data Source
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AI summary
A warehouse management system and a method, the warehouse management system comprising: a control server (110), configured to assign a first sub-order to a first workstation, send a first transport instruction to a first storage container transport device (140), assign a second sub-order to a second workstation, send a second transport instruction to a second storage container transport device (150), and after a picking task corresponding to any sub-order is completed, send a third transport instruction to an order container transport device; a first storage container transport device (140), configured to transport, in response to the first transport instruction, a first storage container to the first workstation; a second storage container transport device (150), configured to transport, in response to the second transport instruction, a second storage container to the second workstation; and an order container transport device, configured to transport, in response to the third transport instruction, an order container for which picking has been completed at the first workstation to the second workstation, or, transport an order container for which picking has been completed at the second workstation to the first workstation.