Warehouse Runner and Picker Layout for Dense Order Fulfillment
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Solution Overview
Problem
Conventional warehouse operations rely heavily on human labor for order fulfillment, which is inefficient and costly, and existing automated systems like ASRS and conveyors require significant investment and space, limiting operational density and efficiency.
Innovation Solution
A system comprising a master server that coordinates a network of runner apparatuses and picker apparatuses, where runner apparatuses retrieve boxes from shelves and position them for picker apparatuses to pick items using robotic arms and vacuum grippers, allowing for efficient item selection and transfer to destination boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated storage and retrieval systems (ASRS) are used to load items from storage locations, then automation of item retrieval is improved, but the system becomes expensive and requires significant space
Solution Approach 1:
The system divides the warehouse into discrete storage locations arranged in a grid pattern, with each location independently addressable by coordinate pairs. Runner apparatuses are segmented into modular units that can independently navigate and service different storage locations, allowing the system to scale automation without requiring a monolithic ASRS infrastructure that would consume excessive space.
Solution Approach 2:
The patent introduces runner apparatuses as intermediary devices between storage locations and picking stations. These runners act as mobile mediators that transport items horizontally across the warehouse floor and vertically between levels, eliminating the need for expensive overhead ASRS mechanisms while maintaining automated retrieval capabilities through a simpler, space-efficient ground-level infrastructure.
2Productivity
If conveyors are used to transport items or boxes around the warehouse, then item transport efficiency is improved, but the system becomes expensive and requires significant space
Solution Approach 1:
The system replaces static conveyor infrastructure with dynamic, mobile runner apparatuses that can adapt their paths and destinations in real-time. These runners dynamically navigate to picking stations based on current order requirements, providing flexible transport efficiency without the fixed space commitments and high installation costs of traditional conveyor systems.
Solution Approach 2:
The patent substitutes complex mechanical conveyor systems with a simpler network of mobile robotic runners that use autonomous navigation and modular design. This substitution maintains transport productivity while dramatically reducing the space required for infrastructure and eliminating the need for expensive mechanical installation and maintenance of conveyor networks.
3Quantity of substance
If the layout of the warehouse is changed by adding shelves, then storage capacity is improved, but significant work is necessary to install new conveyors
Solution Approach 1:
The runner apparatuses are designed as universal, multi-functional units that can service any storage location in the grid-based system regardless of shelf configuration. When shelves are added or reconfigured to increase storage capacity, the same runners can adapt to the new layout without requiring specialized installation or reconfiguration, eliminating the need for new conveyor systems and reducing installation effort to minimal programming updates.
4Adaptability or versatility
If the number of picking stations is changed or processing order is changed, then order fulfillment flexibility is improved, but change in conveyor lines network is required
Solution Approach 1:
The system uses dynamic runner apparatuses that can be programmatically reassigned to different picking stations and processing sequences without physical reconfiguration. When order fulfillment requirements change or new picking stations are added, the master server simply updates the routing logic for runners, providing high adaptability without the complexity of modifying physical conveyor networks.
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 system enhances order fulfillment efficiency by automating the picking process, reducing labor costs, and optimizing space usage, enabling higher item throughput with a smaller footprint.
Implementation Method 1
a vacuum cup configured to pick up the object
Data Source
AI summary
A method for fulfillment of an order includes receiving, at a master server, a specification of the order including a set of items. The master server selects a runner apparatus and transmits a first command to that apparatus to retrieve a first box for presentation to a picker apparatus, where the first box has an item for fulfillment of the order. The runner apparatus retrieves the first box and presents it to the picker apparatus by moving near the picker apparatus, where the picker apparatus includes a base portion that is immovable, and holding the box for access by the picker apparatus. The master server instructs the picker apparatus to sort that item from the first box to a destination box. The picker apparatus picks the item out of the box via a robot arm of the picker apparatus, and moves it to the destination box.