Multi-Storey Warehouse Robot Control for Cross-Layer Picking
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Solution Overview
Problem
Current multi-layer picking schemes in warehousing, particularly those using three-dimensional shuttle vehicles, face challenges such as high construction costs, complex maintenance, and safety concerns due to stringent requirements for shelf precision and ground flatness, as well as difficulties in flexible allocation and container cross-layer transportation.
Innovation Solution
A robot control system comprising a storage region with a loft having multiple storeys, a lifting machine, and self-driven robots that can move through passages on each floor, where a control device assigns transportation tasks and plans routes for the robots to pick up and transport containers between storeys, eliminating the need for shuttle tracks and enhancing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If three-dimensional shuttle vehicle scheme is used, then multi-layer picking in three-dimensional space is achieved, but construction cost increases and maintenance complexity increases
Solution Approach 1:
The system divides the warehouse into multiple storeys with independent mobile robots operating on each floor. Instead of a single complex three-dimensional shuttle vehicle, multiple simpler two-dimensional mobile robots are deployed, each capable of independent operation on its designated storey, thereby reducing overall system complexity while maintaining multi-layer picking capability
Solution Approach 2:
The lifting machine serves as an intermediary device that transports mobile robots and containers between storeys. This mediator enables vertical transportation without requiring complex three-dimensional movement mechanisms, allowing the system to achieve multi-layer operation through coordinated horizontal and vertical transport stages
2Extent of automation
If three-dimensional shuttle vehicle is used, then automated picking is achieved, but ground flatness requirements increase and reliability decreases
Solution Approach 1:
The automated picking function is segmented into independent mobile robots that operate autonomously on each storey. Each robot is equipped with its own navigation and control systems, allowing them to adapt to local ground conditions independently, thereby maintaining reliability even when ground flatness varies across different areas
Solution Approach 2:
The mobile robots employ dynamic navigation capabilities with real-time path planning and adjustment. They can adapt their movement paths to accommodate ground variations, obstacles, and changing conditions, ensuring reliable automated operation without requiring perfectly flat surfaces throughout the warehouse
3Productivity
If three-dimensional shuttle vehicle with conveyance line is used, then container cross-layer transportation is achieved, but flexibility decreases and device complexity increases
Solution Approach 1:
The system employs dynamic task assignment and route planning for mobile robots. The control device can reallocate robots to different storeys and tasks based on real-time requirements, and robots can dynamically adjust their paths. This dynamic flexibility allows the system to adapt to changing operational needs without requiring fixed conveyance lines
Solution Approach 2:
Mobile robots are designed as multi-functional units that can perform various operations including container transport, order picking, and relocation across different storeys. A single robot type can serve multiple functions and locations, replacing the need for specialized conveyance lines for different routes and operations, thereby enhancing flexibility while maintaining productivity
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
This solution reduces construction costs, simplifies maintenance, and improves operational efficiency by allowing self-driven robots to navigate and transport containers across storeys without the need for specialized tracks, enhancing flexibility and safety in warehousing operations.
Implementation Method 1
a lifting machine, configured to transport the at least one self-driven robot or the container to a target storey corresponding to a transportation task
Data Source
AI summary
Disclosed are a robot control system and method. The robot control system includes a storage region, a lifting machine, a control device, and a self-driven robot. The storage region includes a loft having at least two storeys and is configured to store a container, and there is provided a passage on the floor of each of the at least two storeys of the loft for the self-driven robot to move through. The lifting machine is configured to transport the self-driven robot or the container to a target storey corresponding to a transportation task. The control device is configured to assign the transportation task to the self-driven robot and plan a travel route on the target storey for the self-driven robot according to the transportation task, and dispatch the self-driven robot to travel according to the travel route to perform the transportation task.