Warehouse Robot Tray Handling for Back-Row Shelf Retrieval
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Solution Overview
Problem
Current warehouse robot systems lack the capability to efficiently extract and store inventory materials from designated shelves, especially in crowded and obstacle-filled environments, and struggle with processing inventory materials whose positions have been transferred.
Innovation Solution
A method for controlling a warehouse robot to store and fetch inventory materials involves receiving instructions, acquiring positioning information, and using a material handling device to fetch and store materials, while navigating through crowded spaces and handling materials in front and back rows of shelves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a fully automated machine system is implemented to fetch and store inventory materials, then automation level and efficiency are improved, but the system cannot handle complex scenarios such as extracting materials from crowded shelves with multiple rows, navigating obstacles, and processing transferred inventory positions
Solution Approach 1:
The patent segments the shelf into multiple rows (first row, second row, third row, etc.) and implements a systematic approach to handle materials in different rows. The control system divides the complex task of fetching materials from crowded shelves into sequential sub-tasks: detecting material positions, determining row depth, extending the mechanical arm to appropriate depths, and handling materials in a structured sequence. This segmentation enables the automated system to manage complex shelf configurations that would otherwise be impossible to handle.
Solution Approach 2:
The patent implements dynamic adjustment of the mechanical arm's extension depth based on real-time detection of material positions and row configurations. The system dynamically adapts its behavior by adjusting the extension distance to reach materials in different rows (first row, second row, third row), and by dynamically modifying the fetching sequence based on detected material locations. This dynamic capability allows the automated system to handle varying shelf configurations and obstacle positions, significantly improving adaptability while maintaining full automation.
2Ease of operation
If the mechanical arm extends to the back row to fetch the first inventory material, then the ability to access hidden materials is improved, but the risk of collision with front row materials and the complexity of position detection increase
Solution Approach 1:
The patent implements preliminary detection and planning actions before the mechanical arm extends to the back row. The control system first detects the positions of all inventory materials, determines which row each material is in, and plans the fetching sequence to minimize collision risks. By performing these preliminary actions—detection, row assignment, and sequence planning—before the actual fetching operation, the system can safely extend the mechanical arm to the back row without colliding with front row materials, while maintaining easy access to hidden inventory.
Solution Approach 2:
The patent employs continuous feedback mechanisms during the mechanical arm's extension and material fetching process. The detection system monitors the arm's position, the extension depth, and the locations of materials in real-time. Based on this feedback, the control system dynamically adjusts the extension distance and fetching sequence to avoid collisions with front row materials. This feedback loop enables the system to safely access back row materials while preventing harmful collisions, resolving the contradiction between access capability and collision risk.
3Quantity of substance
If the shelf is arranged with multiple rows to increase storage capacity, then the storage density is improved, but the area occupied by the shelf in the warehouse is reduced, making it harder to fetch hidden materials
Solution Approach 1:
The patent segments the detection process into row-specific detection tasks. The control system identifies and detects materials in the first row, second row, third row, and subsequent rows separately and systematically. By dividing the detection task by rows, the system can efficiently handle multi-row shelf configurations with high storage capacity without being overwhelmed by detection complexity. Each row is detected and processed in a structured manner, enabling the system to manage dense shelf arrangements effectively.
Solution Approach 2:
The patent implements dynamic detection and adjustment based on the actual shelf configuration and material positions. The system dynamically adapts its detection strategy to the specific row structure, adjusting the detection depth and sequence based on which rows contain materials. This dynamic detection approach allows the system to efficiently handle high-density multi-row shelves, reducing the effective detection complexity while maintaining high storage capacity. The system only focuses detection efforts on rows that actually contain inventory, optimizing the detection process for dense shelf configurations.
Data Source
AI summary
The disclosure relates to a method for controlling a warehouse robot to store and fetch inventory materials. The method includes: instructing a material handling device to fetch a second inventory material located in the front row, and placing the second inventory material on a first tray; instructing the material handling device to fetch a first inventory material located in the back row, and placing the first inventory material on a second tray; and instructing the material handling device to return the second inventory material to the front row. By instructing the material handling device to fetch the inventory materials and storing the inventory materials in the trays, the inventory materials can be extracted from a designated shelf and stored in a warehouse, navigation is realized in a crowded warehouse filled with obstacles, and the inventory materials whose positions have been transferred can be processed.