Warehouse Robot Coordination for Mixed-Size Inventory Structures
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Solution Overview
Problem
Current materials handling systems in warehouses face inefficiencies due to the need for identical or multiple sizes of inventory structures and robots, leading to wasted space, increased maintenance, and higher costs, as they must be sized for the largest SKU or have multiple robot types to accommodate different structure sizes.
Innovation Solution
A method and system where a plurality of differently sized inventory structures are transported by a plurality of robots connected in a wireless network, with a control system that determines the number of robots and lifting locations based on structure design and load, allowing for flexible and efficient movement of structures of varying sizes using identical robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If identically sized inventory structures are used for all SKUs, then robot design and operation are simplified, but space is wasted because structures must be sized for the largest SKU
Solution Approach 1:
The system segments the inventory structure population into multiple size categories (small, medium, large structures) rather than using a single uniform size. Each structure type is optimized for specific SKU dimensions, eliminating wasted space while robots handle different structure types through standardized lifting locations.
2Loss of substance
If differently sized robots are used for different structure sizes, then space utilization is optimized, but maintenance overhead and costs increase
Solution Approach 1:
The patent makes robots universal by equipping them with multiple lifting locations that can accommodate different structure sizes. A single robot design with configurable lifting points can handle small, medium, and large structures, eliminating the need for multiple robot types and reducing maintenance overhead while maintaining optimized space utilization.
3Device complexity
If identically sized robots capable of moving all structure sizes are used, then robot fleet management is simplified, but costs increase because robots must be sized for the largest structure
Solution Approach 1:
The system introduces dynamics by allowing robots to configure their lifting capacity based on the specific structure being moved. Instead of all robots being statically sized for the largest structure, each robot can adapt its effective capacity by selecting appropriate lifting locations, reducing costs while maintaining management simplicity.
4Adaptability or versatility
If multiple robot types are used for different structure sizes, then each robot can be optimized for its specific size, but system complexity and coordination difficulty increase
Solution Approach 1:
The patent applies homogeneity by standardizing the robot design and lifting location interfaces across all robots. This uniform approach allows different structure sizes to be handled by the same robot type through configuration rather than requiring multiple specialized robot types, reducing system complexity while maintaining optimized matching between robots and structures.
Data Source
AI summary
A method for transporting items in a system including plural structures of different designs, plural robots connected in a wireless network for transporting the plural structures, and a control system connected in the wireless network. The method includes: receiving, by the control system, a transport request indicating a structure to be transported from a current location to a new location and determining, by the control system, based on the transport request, a number of robots to assign to the transport request. The method further includes: coordinating, by the control system, a lift operation by the number of robots of the structure, wherein during the lift operation each robot engages with a lifting location associated with the structure, and coordinating, by the control system, transport, by the number of robots, of the structure to the new location.