Warehouse Control System Using Pneumatic Pusher for Rack Automation
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Solution Overview
Problem
Current automatic warehouse systems are inefficient and costly due to high hardware requirements and reduced storage density, as they necessitate complex robotic navigation and obstacle avoidance, making them difficult to implement and manage.
Innovation Solution
An automatic warehouse control system comprising a goods transport module, information input module, data storage module, and drive control module, which uses a barcode or RFID scanner for inputting and retrieving goods information, and a pneumatic cylinder-driven container driving device for moving goods containers on a rack to a designated picking location, allowing for efficient and cost-effective management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot with optical sensors and infra-red sensors is used to transport racks and goods containers, then the warehouse automation level is improved, but the hardware cost and system complexity increase significantly
Solution Approach 1:
The patent replaces complex robotic systems with optical sensors and infra-red sensors with a simple mechanical pusher device. The pusher mechanically pushes goods containers along the rack without requiring any sensing, navigation, or autonomous decision-making capabilities. This mechanical substitution dramatically reduces hardware complexity while maintaining automated functionality through centralized control.
Solution Approach 2:
The patent uses simple, inexpensive mechanical components (pusher, rack, goods containers) instead of expensive, complex robotic systems. The pusher is a basic mechanical device that can be easily manufactured and replaced if needed, rather than requiring costly robotic arms with multiple sensors and control systems.
2Ease of operation
If space is left in the racks for movement of the robot and goods containers, then the robot can transport goods, but the density of the goods container arrangement is reduced
Solution Approach 1:
The patent segments the rack into multiple levels (first rack body and second rack body) with goods containers arranged on different levels. The pusher operates on specific levels to push containers horizontally, while vertical stacking maximizes space utilization. This segmentation allows dense arrangement without requiring horizontal movement space for robots.
Solution Approach 2:
Instead of having the robot move through aisles between racks (requiring horizontal space), the patent inverts the approach by having a pusher move containers horizontally on the rack faces while containers are stacked vertically. This inversion of the movement direction (from aisle-based to rack-face-based) eliminates the need for aisle space while maintaining transport capability.
3Productivity
If workers or stackers move back and forth along aisles to pick and place goods, then goods can be retrieved, but the warehouse management efficiency is poor
Solution Approach 1:
The system implements self-service through automated control. When a goods retrieval request is received, the control device automatically determines the optimal pusher, calculates the pushing distance, and controls the pusher to transport the goods container to the collection station without human intervention. This eliminates the need for workers to manually search and retrieve goods, dramatically improving efficiency and reducing time loss.
Solution Approach 2:
The patent implements preliminary action by pre-arranging goods containers on the rack in an organized manner and pre-calculating the optimal pushing paths and distances. The control device stores information about container positions and uses this preliminary data to quickly determine retrieval operations, avoiding time-consuming searches and manual decision-making during actual goods retrieval.
Data Source
AI summary
An automatic warehouse control system and method are provided. The system comprises a goods transport module, an information input module, a data storage module, a data retrieval module, and a drive control module. The goods transport module moves goods containers. The information input module is configured to input goods information to form goods warehousing data. The data storage module stores the goods warehousing data. The data retrieval module retrieves goods warehousing data and sends a retrieved result to the drive control module according to information of to-be-picked goods. The drive control module controls operation of the goods transport module to transport a goods container containing the to-be-picked goods to the goods-picking location according to the retrieved result. The technical solution is easy to implement, has a low cost, and allows one warehouse operator to manage multiple racks at the same time, which can significantly reduce hardware and time cost.