DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of Invention:
A SYSTEM AND METHOD FOR HIGH THROUGHPUT PICKING OF GOODS FROM A WAREHOUSE INVENTORY

APPLICANT:
ARAPL RAAS PRIVATE LIMITED
An Indian entity having address as:
Gat No.1209, Village Wadki, Pune-412308, Maharashtra, India.

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from the Indian patent application, having application number 202321005559, filled on 27th January 2023, incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure relates to a supply chain, manufacturing, and logistics automation equipment systems, and more particularly to a high throughput picking of SKU cartons/bins from an inventory storage using a smart robot.
BACKGROUND
This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
In logistics facilities, such as distribution centers or warehouses, goods are stored for retrieval by a pick worker. Each type of item is known as a Stock Keeping Unit (SKU), and each SKU has a specific location in which it is kept. These items can be stored openly on shelving racks, or in compartmentalized containers, such as boxes or bins. Companies that sell goods online have a central warehouse where they store their inventory and send items to customers when they receive order. Generally, the central warehouses have large space as an inventory storage which is used to serve as space for inward goods, space for outward goods ordered by the customers and space for other remaining goods. The inventory storage generally comprises a set of racks of height of 2 meters, as a human being can pick items only up to a height of 6 feet. Typically, a warehouse person needs to pick goods SKU cartons from the inventory storage of the central warehouse. For which, the warehouse person then must walk through all the SKU cartons in the inventory storage of the central warehouse for picking items ordered by the customer.
There are numerous issues associated with this manual way of picking SKU cartons from the inventory storage such as, walking around the large inventory storage by a pick worker consumes around 70% of his/her total working time. By walking around the inventory storage, an individual pick worker on an average pick approx. 70-100 units per hour, even when the pick worker is provided with a handheld device having a guided path of the inventory storage. Hence, the warehouses/logistics facilities facilitating manually picking requires large number of pick workers for picking the items from the inventory storage for fulfilling customer orders. Further, manually picking the SKU cartons from the inventory storage is time-consuming and a difficult task. This is because, manually searching the SKU carton at inventory storage requires plenty of time and identifying a relevant item from the entire inventory is a complex task. Also, the warehouse person generally can only pick items in the inventory storage shelves up to a height of 2 meters, which increases the size requirement of the inventory storage.
Picking items from the inventory storage shelves of height more than 2 meters is even more time consuming and complicated task. The manual collection of SKU cartons from the inventory storage can inevitably entails a risk of human error (i.e., risk of picking non-relevant items from the whole inventory storage is high). Further, high number of warehouse persons are required for manual picking of goods SKU cartons.
Therefore, there is a long-felt need for a method and a system that overcome the at least the issues/challenges related to the manual picking of SKU cartons/bins from the inventory storage and facilitating high throughput picking of SKU cartons from the inventory storage of the central warehouse.
SUMMARY
This summary is provided to introduce concepts related to a system and a method for high throughput picking of SKU cartons from an inventory storage of a logistic facility such as a warehouse, and the concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in classifying or limiting the scope of the claimed subject matter.
In one implementation, a system for high throughput picking of goods from a warehouse inventory is disclosed. The system may comprise a memory and a processor. The processor may be coupled with the memory. The processor may be configured to execute programmed instructions stored in the memory. The system may comprise an intelligent warehouse management system (IWMS). The IWMS may be coupled with the memory and the processor. The IWMS may be configured to enable the high throughput picking operations. Further, a centralized warehouse may comprise an inventory storage and a pick zone. The inventory storage may comprise a plurality of storage compartments for one or more cartons. Each compartment from the plurality of storage compartments may be associated with a corresponding compartment identifier. Each carton from the one or more cartons may be associated with a corresponding carton identifier. Further, the pick zone may comprise a set of bins for temporarily carrying one or more cartons for picking. Furthermore, one or more smart robots may be communicatively connected to the IWMS for performing high throughput picking operations. In one embodiment, the IWMS may be configured to receive one or more order information related to one or more items stored in the one or more cartons placed in the plurality of storage compartments. Furthermore, the one or more one or more smart robots may be configured to receive one or more transport instructions from the IWMS. One or more transport instructions may correspond to instructions for transporting one or more cartons from the plurality of storage compartments of the inventory storage to the set of bins of the pick zone for temporarily carrying one or more cartons for picking. Furthermore, the one or more smarts robots may be configured to navigate to the inventory storage for picking the one or more cartons, based on the received transport instructions. The one or more smarts robots may be configured to pick one or more cartons from the plurality of storage compartments of the inventory storage. Moreover, the one or more smart robots may be configured to bring the one or more cartons from the inventory storage to the pick zone. The one or more smart robots may further be configured to place the brought out one or more cartons to the set of bins of the pick zone, for picking one or more items from the one or more cartons. Further, the one or more smart robots may be configured to place one or more residual cartons from the set of bins of pick zone back to the plurality of inventory storage. Furthermore, the one or more smart robots may be configured to update the IWMS with mapping of carton identifier of one or more residual cartons with compartment identifier of the inventory storage on which the one or more residual cartons have been placed.
In another implementation, a method for high throughput picking of goods from a warehouse inventory by an intelligent warehouse management system (IWMS) using one or more smart robots is disclosed. The method comprises one or more steps of receiving one or more order information related to one or more items stored in one or more cartons placed in an inventory storage of a centralized warehouse. The inventory storage may comprise a plurality of storage compartments for storing one or more cartons. Each carton from one or more cartons may be associated with a corresponding carton identifier. Each compartment from the plurality of storage compartments may be associated with a corresponding compartment identifier. Further, the method may comprise the step of sending one or more transport instructions to the one or more one or more smart robots for transporting one or more cartons to a pick zone of the centralized warehouse. The pick zone may comprise a set of bins for temporarily carrying one or more cartons for picking. Further, the set of bins in the pick zone may be associated with a corresponding bin identifier. Further, the method may comprise step of enabling one or more smart robots to navigate to the inventory storage for picking the one or more cartons based on the received transport instructions. Further, the method may comprise step of enabling one or more smart robots to pick one or more cartons from the plurality of storage compartments of the inventory storage. The method may further comprise step of enabling one or more smart robots to bring the one or more cartons from the inventory storage to the pick zone. The method may further comprise the step of enabling one or more smart robots to place the brought out cartons to the set of bins of the pick zone for picking one or more items from the one or more cartons. Further, the method may comprise the step of enabling one or more smart robots to place one or more residual cartons from the set of bins of pick zone back to the plurality of storage compartments of the inventory storage. Moreover, the method may comprise the step of updating the IWMS with mapping of carton identifier of one or more residual cartons with compartment identifier of the inventory storage on which the one or more residual cartons have been placed.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF DRAWINGS
The detailed description is described with reference to the accompanying figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer to the like features and components.
Figure 1 illustrates a system (100) for high throughput picking of goods from an inventory storage of a central warehouse (200), in accordance with an embodiment of the present subject matter.
Figure 2 illustrates the estate architecture of the central warehouse (200) comprising an inventory storage (201), a pick zone (202), and a packing and billing station (203), in accordance with an embodiment of the present subject matter.
Figure 3a illustrates a flow diagram (300) describing method steps to be performed for high throughput picking of goods from the inventory storage (201) of the central warehouse (200), in accordance with an embodiment of the present subject matter.
Figure 3b illustrates a flow diagram (300) describing method steps to be performed in a packing and billing station (203) of the central warehouse (200), in accordance with an embodiment of the present subject matter.
Figure 4A-4B illustrates a flowchart describing a method (400) for high throughput picking of goods from a warehouse inventory, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
Before the present system and method are described, it is to be understood that this disclosure is not limited to the system and its arrangement as described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. The present disclosure overcomes one or more shortcomings of the prior art and provides additional advantages discussed throughout the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the versions or embodiments only and is not intended to limit the scope of the present application.
The terms “comprise”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system or method. In other words, one or more elements in a system or apparatus preceded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
Referring to Figure 1, a system (100) for high throughput picking of SKU carton from an inventory storage of a central warehouse, is illustrated in accordance with an embodiment of the present subject matter. The system (100) may comprise an intelligent warehouse management system (IWMS) (102), a user device (104), and a one or more smart robots (106). The central warehouse (200) may be divided into three sections namely an inventory storage (201), a pick zone (202), and a packing and billing station (203). The details of the sections are given in subsequent paragraphs with reference to the figure 2. The IWMS (102), the user device (104) and the one or more smart robots (106) may communicate to send or receive data with each other through a network (108). The network (108) may comprise any one of the following: a cable network, a wireless network, a telephone network (e.g., Analog, Digital, POTS, PSTN, ISDN, xDSL), a cellular communication network, a mobile telephone network (e.g., CDMA, GSM, NDAC, TDMA, E-TDMA, NAMPS, WCDMA, CDMA-2000, UMTS, 3G, 4G, 5G, 6G), a radio network, an Internet, an Intranet, a local area network (LAN), a wide area network (WAN), or short-range communication network. However, the network used for communication is not limited to the above example, a person skilled in the art may use any other communication means known to a person skilled in the art. The system (100) may comprise a memory and a processor. The processor may be coupled with the memory. The processor may be configured to execute programmed instructions stored in the memory. The IWMS (102) may comprise a memory and a processor coupled to the memory. The IWMS (102) may be configured to enable the high throughput picking operations of the centralized warehouse (200). The IWMS may be coupled with the memory and the processor. The processor may be configured to execute programmed instructions stored in the memory for controlling and tracking the one or more smart robots (106) for high throughput picking of goods from the inventory storage (201) of the central warehouse (200). The IWMS (102) can be implemented using hardware, software, or a combination of both, including using where suitable, one or more computer programs, mobile applications or “apps” by deploying either on-premises over the corresponding computing terminals or virtually over cloud infrastructure. The IWMS (102) may comprise various micro-services or groups of independent computer programs which can act independently in collaboration with other micro-services. The IWMS (102) may also interact with a third-party or external computer system. Internally, the IWMS (102) may be the central processor of all requests for transactions by the various actors or users of the system. A critical attribute of the IWMS (102) is that it is able to concurrently and instantly complete an online transaction by a system user in collaboration with other systems.
The processor, in one embodiment, may comprise a standard microprocessor, microcontroller, central processing unit (CPU), distributed or cloud processing unit, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions and/or other processing logic that accommodates the requirements of the present invention. The memory, in another embodiment, may include any computer-readable medium or computer program product known in the art including, for example, volatile memory, such as static random-access memory (SRAM) and dynamic random-access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, Solid State Disks (SSD), optical disks, magnetic tapes, memory cards, virtual memory and distributed cloud storage. The memory may be removable, non-removable, or a combination thereof. The memory may include routines, programs, objects, components, data structures, etc., which perform particular tasks or implement particular abstract data types. The memory may include programs or coded instructions that supplement applications and functions of the system (100). In one embodiment, the memory, amongst other things, serves as a repository for storing data processed, received, and generated by one or more of the programs or the coded instructions. In yet another embodiment, the memory may be managed under a federated structure that enables adaptability and responsiveness of the system (100). In one embodiment, the IWMS (102) utilizes the processor for executing the programmed instructions stored in the memory.
In one embodiment, the one or more smart robots (106) may comprise a motorized base, one or more shelves, a manipulator, an extendable lift, a processor, a memory, a communication module, and a power storage unit. A shelf from one or more shelves may be configured for picking and placement of the one or more cartons. A plurality of storge compartments may comprise height in the range of 500 to 3700 mm. In one embodiment, the one or more smart robots (106) may be a line tracing robot. In some embodiments, the motorized base is also equipped with a LIDAR system to assist in navigating the distribution site and avoiding obstacles. The LIDAR system emits lasers or light (e.g., ultraviolet, visible, or near infrared light) and analyses the reflection to image the surrounding area and identify safe navigable pathways. Underneath the motorized base are casters, drive wheels, and motors that allow the one or more smart robots (106) to move along x-y spatial planes within the central warehouse. In some embodiments, the extendible lift may be coupled to motors at the base. In another embodiments, the extendible lift may be coupled to a drive motor independent of the motors powering the robot wheels. The extendible lift may be a folding or collapsible framework that can expand to several heights. When fully collapsed, the extendible lift rises about one foot above the motorized base in some embodiments. When fully expanded, the extendible lift may rise over four meters above the motorized base in some embodiments. In some other embodiments, the motor powers the extendible lift pneumatically or with other mechanical means. Further, the one or more smart robots (106) may comprise one or more optical sensors for ex. Camera for scanning the machine-readable code. One or more smart robots (106) may comprise multiple storage racks for carrying multiple cartons simultaneously. The IWMS (102) may control the operation and movement of the one or more smart robots (106). The communication module of the one or more smart robots (106) may be configured to send or receive information from the IWMS (102), and automatically perform high throughput picking operations.
The one or more user device (104) may comprise a variety of portable electronic devices, including but not limited to cellular devices, mobile device, tablets, portable digital assistants (PDAs), laptop computers, netbooks, smart books, and the like. An application associated with the IWMS (102) may be installed on the user device (104). The user device (104) may comprise a communication module to communicate with the IWMS (102). Further, the user device (104) may comprise one or more optical sensors for ex. Camera for scanning the machine-readable code.
Now referring to the Figure 2, an estate architecture of a central warehouse (200) is illustrated, in accordance with an embodiment of the present subject matter. The central warehouse (200) may comprise an inventory storage (201), a pick zone (202), and a packing and billing station (203). The inventory storage (201) may correspond to a main storage area for storing all goods SKU cartons. The inventory storage (201) may comprise a set of racks with a set of compartments for storing the SKU cartons. Each compartment of the inventory storage (201) may correspond to a compartment identifier mapped to a compartment machine-readable code. The compartment machine-readable code may be pasted to each compartment of the inventory storage (201). The racks of the inventory storage (201) may be of a height up to 4 meters or more. Storage at high shelving racks more than 4 metre may reduce the storage area of the inventory storage (201). The plurality of storage compartments corresponds to the multiple storage compartments that may be positioned above a typical height of human, constituting an arrangement of storage compartments elevated beyond human reach. The machine-readable code may comprise one of the following: a linear barcode, a radio frequency identification (RFID) tag, a Quick Response (QR) code, an optical label or the like. The pick zone (202) may correspond to an area for temporarily storing SKU cartons of customer ordered goods. The Pick zone (202) may be used to facilitate quick picking of customer ordered goods by a pick worker (not illustrated in Figures). The pick zone (202) may be used to receive SKU cartons from the inventory storage (201). The Pick zone (202) may comprise a set of racks with a set of bins for storing the SKU cartons. Each bin of the Pick zone (202) may correspond to a bin identifier mapped to a bin machine-readable code. The bin machine-readable code may be pasted to each bin of the Pick zone. The racks of the Pick zone (202) may be of a height up to 2 meters. Storage at 2-meter racks may be easy for the pick worker for picking the customer ordered goods. The pick worker may be a person who picks the customer ordered goods from the SKU carton, based on customer order information, in the Pick zone (202) of the central warehouse (200). The packing and billing station (203) may correspond to an area to facilitate packing of the customer ordered goods and generating billing information for the customer ordered goods. The packing and billing station (203) may receive customer ordered goods from the Pick zone (202). Each carton from the one or more cartons is associated with a corresponding carton identifier mapped with a carton machine-readable code. In an embodiment of the present disclosure, each of the compartment machine-readable code, carton machine-readable code, and bin machine-readable code may correspond to one of a linear barcode, radio frequency identification (RFID) tag, quick response (QR) code, optical label, or a combination thereof. The plurality of storage compartments at the inventory storage (201) and plurality of bins at the pick zone (202) are different and placed at different locations in the central warehouse (200). In one embodiment, the one or more user device (104) of the system (100) may be configured to update mapping information of residual carton identifier with a compartment identifier of the inventory storage (201), to the IWMS (102). The update of mapping information to the IWMS (102) is performed by first scanning a compartment machine-readable code and then the carton machine-readable code of the residual cartons by the user device (104) and vice versa. In one embodiment, the one or more user device (104) of the system (100) may be configured to update mapping information of carton identifier with a bin identifier of the pick zone (202), to the IWMS (102). The update of mapping information to the IWMS (102) is performed by first scanning a bin machine-readable code and then the carton machine-readable code by the user device (104) and vice versa. In yet another embodiment, one or more smart robots (106) of the system (100) may be configured to update mapping information of carton identifier with a bin identifier of the pick zone (202), to the IWMS (102). The update of mapping information to the IWMS (102) is performed by first scanning a bin machine-readable code and then the carton machine-readable code by the smart robot (106) and vice versa.
The method steps performed in the inventory storage (201), the pick zone (202), and the packing and billing station (203) may be described in detail with reference to figures 3a and 3b in subsequent paragraphs.
Now referring to figure 3a, a flow diagram (300) describing method steps to be performed for picking and transferring a goods from the inventory storage (201) to the pick zone (202) are illustrated, in accordance with an embodiment of the present subject matter. The method steps to be perform at the inventory storage (201) and the Pick zone (202) may be as follows:
In step 301, a customer may place an order for an item on an online platform. The online platform may be an e-commerce website. The customer may place order by making a phone call. The IWMS (102) may receive order details from the online platform.
In step 302, the IWMS (102) may be configured to launch the order details. The launching of order details may comprise sending order related details to a concerned service.
In step 303, the IWMS (102) may send one or more transport instructions to the one or more smart robots (106) for picking the one or more cartons corresponding to customer ordered goods from a specific location of the Inventory storage (201) and transferring the picked SKU carton to the Pick zone (202) of the central warehouse (200). The one or more transport instructions may correspond to transporting one or more cartons from the storage compartments of the inventory storage (201) to the set of bins of the pick zone (202) for temporarily carrying one or more cartons for picking. In one implementation, one or more transport instructions may correspond to an immediate instruction, needs to be followed by the one or more smart robot (106) on urgent basis. In another implementation, one or more transport instructions may correspond to the scheduled instructions for future processing by the one or more smart robots (106). The IWMS (102) may also send the shortest traveling path (along with picking instructions) to reach the inventory storage (201). The IWMS (102) may also assign priority to the instructions to be sent to the one or more smart robots (106) based on order priority In an exemplary embodiment, one or more transport instructions comprise one of the carton identifiers, the bin identifier, the compartment identifier, location (geo-spatial) coordinates of the plurality of bins of the pick zone, location (geo-spatial) coordinates of the plurality of storage compartments of the inventory storage, a shortest travelling path or a combination thereof. The one or more smart robots (106) may then move towards the inventory storage (201).
In step 304, the one or more smart robots (106) may scan the machine-readable code of each carton from the one or more cartons at the inventory storage (201) to verify the instructions (each carton Identifier, compartment identifier) received from the IWMS (102). After successful verification (in step 305) the one or more smart robots (106) may pick the one or more cartons from the compartment of the inventory storage (201) and move towards the pick zone (202). In another embodiment, the one or more smart robots (106) may pick the one or more cartons from the compartment of the inventory storage (201), based on geo-spatial coordinates received from the IWMS (102). The one or more smart robots (106) might not be able to scan either the compartment machine-readable code for the compartment if another carton has previously been placed in that location, or not be able to scan each carton from the one or more cartons of the Inventory storage (201). The IWMS (102) may assign another SKU carton location for picking and may then send instructions to the one or more smart robots (106). The IWMS (102) may also report error in the system related to the machine-readable code verification.
In step 305, the one or more smart robots (106) may pick the one or more carton from the compartment of the inventory storage (201) and move towards the Pick zone (202). The one or more smart robots (106) may utilize an optimized path to reach the pick zone (202).
In step 306, the one or more smart robots (106) may drop the picked one or more cartons at the Pick zone (202). Dropping each carton to the Pick zone (202) may comprise scanning each bin machine-readable code of the Pick zone (202) by the one or more smart robots (106) to identify an empty bin. After identification of the empty bin, the one or more smart robots (106) may drop the SKU carton to the identified bin. In an embodiment, the one or more smart robots (106) may receive a different compartment identifier, from the IWMS (102), in response to not identifying an empty storage compartment, for storing one or more residual cartons. In another embodiment, the one or more smart robots (106) may drop the picked one or more carton at the Pick zone (202), based on geo-spatial coordinates received from the IWMS (102). The one or more smart robots may send mapping information (i.e., the carton identifier, the bin identifier of the Pick zone 202) to the IWMS (102).
In step 307, the one or more smart robots (106) may be configured to pick Residual one or more carton from the Pick zone (202). Residual one or more cartons may be the one or more cartons of the Pick zone (202) from which a pick worker has picked the customer ordered goods. The one or more smart robots (106) after picking the one or more residual cartons from the Pick zone (202) may move towards the Inventory storage (201). The one or more smart robots (106) may scan the compartment machine-readable code of each compartment of the inventory storage (201). After successfully scanning, the one or more smart robots (106) may place the one or more residual SKU cartons in the compartment of the Inventory storage (201). In another embodiment, the one or more smart robots (106) may place the one or more residual cartons in the compartment of the Inventory storage (201), based on geo-spatial coordinates received from the IWMS (102). The one or more smart robots (106) might not be able to scan the machine-readable code for the compartment if another one or more cartons has previously been placed in that location. The IWMS (102) may assign another location for that placement and may then send instructions to the one or more smart robots (106). The one or more smart robots (106) may place the carton at the compartment of the inventory storage (201).
In step 308, the pick worker may receive the order details on the user device (104). The user device (104) may be connected to the IWMS (102) via an API associated with the IWMS (102). The pick worker, by using the user device (104), may scan the bins of the Pick zone (202) and pick the customer ordered item from the one or more cartons placed on the bin of the Pick zone (202). The one or more cartons from which the pick worker picked the item may become residual carton. The pick worker, after picking, may transfer the one or more residual cartons information (SKU Carton Identifier, Bin identifier) to the IWMS (102) using the user device (104). The pick worker, after picking, may put the item in an order trolly.
Now referring to Figure 3b, a flow diagram describing method steps to be performed in a packing and billing station (203) of the central warehouse (200) are illustrated, in accordance with an embodiment of the present subject matter. The method steps to be perform at the packing and billing station (203) may be as follows:
In step 309, the pick worker may transfer the picked customer ordered item to the packing and billing station (203). At the packing and billing station (203), the customer ordered item may be packed and a bill related to the customer order for the item may be generated. The received order from the customer and customer ordered item may be authenticated at the packing and billing station (203).
In step 310, a person of the packing and billing station (203) may stag the packed item at an outward staging area. The outward staging area may be an area near to the exit gate of the central warehouse (200).
In step 311, the pack item then dispatches to the customer from the outward staging area.
Now referring to Figure 4, a method (400) for high throughput picking of goods from a warehouse inventory, by an Intelligent Warehouse Management System (IWMS) (102) using one or more smart robots (106) is illustrated in accordance with an embodiment of the present disclosure. The method (400) may comprise one or more steps of receiving (401) one or more order information related to one or more items stored in one or more cartons placed in an inventory storage (201) of a centralized warehouse (200). One or more order information, received by the IWMS (102), comprises one or more item names, order quantity, and order priority. Further, the inventory storage (201) may comprise a plurality of storage compartments for storing one or more cartons. Each carton from the one or more cartons may be associated with a corresponding carton identifier. Each compartment from the plurality of storage compartments may be associated with a corresponding compartment identifier. The method may comprise one or more steps of sending (402) one or more transport instructions to the one or more smart robots (106) for transporting one or more cartons to a pick zone (202) of the centralized warehouse (200). The pick zone (202) may comprise a set of bins for temporarily carrying one or more cartons for picking. Further the set of bins in the pick zone (202) is associated with a corresponding bin identifier. Further, the method (400) may comprise one or more steps of enabling one or more robots (106) to perform the following steps. The method (400) comprises a step of enabling one or more robots (106) to navigate (403) to the inventory storage (201) for picking the one or more cartons, based on the received transport instructions. Further, the method (400) may comprise a step of enabling one or more robots (106) to pick (404) the one or more cartons from the plurality of storage compartments of the inventory storage (201). The method (400) may comprise the step of enabling one or more robots (106) to bring (405) the one or more cartons from the inventory storage (201) to the pick zone (202). Further, the method (400) may comprise a step of enabling one or more robots (106) to place (406) the brought out one or more cartons to the set of bins of the pick zone (202) for picking one or more items from the one or more cartons. The picking operation at the pick zone (202) is performed either automatically through one or more smart robots (106), or manually by a pick worker.
The method (400) may comprise the step of enabling one or more robots (106) to place (407) one or more residual cartons from the set of bins of pick zone (202) back to the plurality of storage compartments of the inventory storage (201). Moreover, at step (409) the method may comprise step of updating the IWMS (102) with mapping of carton identifier of one or more residual cartons with compartment identifier of the inventory storage (201) on which the one or more residual cartons have been placed.
The embodiments illustrated above, especially related to an automated system (100) and method for high throughput picking of one or more cartons from an inventory storage (201) of a warehouse, may provide, but are not limited to, following technical advancements:
• Reduction in manpower for picking the one or more cartons from the inventory storage of the warehouse, due to automatic transferring of the one or more cartons from the inventory storage (201) to Pick zone (202).
• Needs less area to store the one or more cartons at inventory storage (201) as one or more smart robots (106) can pick the one or more cartons at high shelving racks up to 4 meters or more.
• Achieve high precision and accuracy of picking of the one or more cartons and eliminate risk of human errors
• One or more smart robots (106) can work 24 hours without rest.
• Save time for picking and transferring the one or more cartons from the inventory storage due to automated robotic transportation and time management by the IWMS. Thus, achieves High throughput of picking of goods from the inventory storage of the warehouse.
Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure.
The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
,CLAIMS:We Claim:
1. A system (100) for high throughput picking of goods from a warehouse inventory, characterized in that, the system (100) comprises:
a memory;
a processor coupled with the memory, wherein the processor is configured to execute programmed instructions stored in the memory;
an intelligent warehouse management system (IWMS) (102) coupled with the memory and the processor, wherein the IWMS (102) is configured to enable the high throughput picking operations;
a centralized warehouse (200), wherein the centralized warehouse (200) comprises an inventory storage (201) and a pick zone (202),
wherein the inventory storage (201) comprises a plurality of storage compartments for storing one or more cartons, wherein each compartment from the plurality of storage compartments is associated with a corresponding compartment identifier, wherein each carton from the one or more cartons is associated with a corresponding carton identifier;
wherein the pick zone (202) comprises a set of bins for temporarily carrying one or more cartons for picking;
one or more smart robots (106), communicatively connected to the IWMS (102), for performing high throughput picking operations;
wherein the IWMS (102) is configured to receive one or more order information related to one or more items stored in the one or more cartons placed in the plurality of storage compartments;
wherein one or more smart robots (106) are configured to:
receive one or more transport instructions, from the IWMS (102), wherein one or more transport instructions correspond to instructions for transporting one or more cartons from the plurality of storage compartments of the inventory storage (201) to the set of bins of the pick zone (202) for temporarily carrying one or more cartons for picking,
navigate to the inventory storage (201) for picking the one or more cartons, based on the received transport instructions;
pick the one or more cartons from the plurality of storage compartments of the inventory storage (201);
bring the one or more cartons from the inventory storage (201) to the pick zone (202);
place the brought out one or more cartons to the set of bins of the pick zone (202) for picking one or more items from the one or more cartons;
place one or more residual cartons from the set of bins of pick zone (202) back to the plurality of storage compartments of the inventory storage (201); and
update the IWMS (102) with mapping of carton identifier of one or more residual cartons with compartment identifier of the inventory storage (201) on which the one or more residual cartons have been placed.
2. The system (100) as claimed in claim 1, wherein the set of bins in the pick zone (202) is associated with a corresponding bin identifier.
3. The system (100) as claimed in claim 2, wherein the compartment identifier corresponds to a compartment machine-readable code; wherein the carton identifier corresponds to a carton machine-readable code; wherein the bin identifier corresponds to a bin machine-readable code; wherein each of the compartment machine-readable code, carton machine-readable code, and bin machine-readable code correspond to one of a linear barcode, radio frequency identification (RFID) tag, quick response (QR) code, optical label, or a combination thereof.
4. The system (100) as claimed in claim 1, wherein one or more order information, received by the IWMS (102), comprises one or more item names, order quantity, and order priority.
5. The system (100) as claimed in claim 1, wherein one or more transport instructions are instructions scheduled for future processing by the one or more one smart robots (106); wherein one or more transport instructions comprise one of the carton identifier, the bin identifier, the compartment identifier, location coordinates of the plurality of bins of the pick zone (202), location coordinates of the plurality of storage compartments of the inventory storage (201), a shortest travelling path or a combination thereof; wherein one or more transport instructions for a carton is generated by the IWMS (102) based on the received order priority in one or more order information.
6. The system (100) as claimed in claim 1, wherein the plurality of storage compartments of the inventory storage (201) and the set of bins of the pick zone (202) are different and placed at different locations in the centralized warehouse (200).
7. The system (100) as claimed in claim 1, wherein the picking operation at the pick zone (202) is performed either automatically through the one or more smart robots (106), or manually by a pick worker.
8. The system (100) as claimed in claim 1, wherein the system (100) comprises one or more user devices (104), wherein the one or more user devices (104) is configured to input, into the IWMS (102) mapping of carton identifier of one or more residual cartons with either the bin identifier or the compartment identifier; wherein the one or more user devices (104) is used, after the manual picking operation by the pick worker, for mapping of carton identifier of the residual carton with the bin identifier of the pick zone (202).
9. The system (100) as claimed in claim 1, wherein the one or more smart robots (106) are configured to receive a different compartment identifier, from the IWMS (102), in response to not identifying an empty storage compartment, for storing one or more residual cartons.
10. A method (400) for high throughput picking of goods from a warehouse inventory, by an Intelligent Warehouse Management System (IWMS) (102) using one or more smart robots (106), characterized in that, the method (400) comprising:
receiving (401) one or more order information related to one or more items stored in one or more cartons placed in an inventory storage (201) of a centralized warehouse (200), wherein the inventory storage (201) comprises a plurality of storage compartments for storing one or more cartons, wherein each carton from the one or more cartons is associated with a corresponding carton identifier, wherein each compartment from the plurality of storage compartments is associated with a corresponding compartment identifier;
sending (402) one or more transport instructions, to the one or more smart robots (106), for transporting one or more cartons to a pick zone (202) of the centralized warehouse (200), wherein the pick zone (202) comprises a set of bins for temporarily carrying one or more cartons for picking, wherein the set of bins in the pick zone (202) is associated with a corresponding bin identifier;
enabling one or more smart robots (106) to:
navigate (403) to the inventory storage (201) for picking the one or more cartons, based on the received transport instructions;
pick (404) the one or more cartons from the plurality of storage compartments of the inventory storage (201);
bring (405) the one or more cartons from the inventory storage (201) to the pick zone (202);
place (406) the brought out one or more cartons to the set of bins of the pick zone (202) for picking one or more items from the one or more cartons;
place (407) one or more residual cartons from the set of bins of pick zone (202) back to the plurality of storage compartments of the inventory storage (201); and
update (408) the IWMS (102) with mapping of carton identifier of one or more residual cartons with compartment identifier of the inventory storage (201) on which the one or more residual cartons have been placed.
11. The method (400) as claimed in claim 10, wherein the method (400) comprises generating, by the IWMS (102), the one or more transport instructions for one or more cartons stored in the plurality of storage compartments of the inventory storage (201) based on order priority received in the one or more order information.
12. The method (400) as claimed in claim 10, wherein one or more transport instructions are instructions scheduled for future processing by the one or more smart robots (106); wherein one or more transport instructions comprise one of the carton identifier, the bin identifier, the compartment identifier, location coordinates of the plurality of bins of the pick zone (202), location coordinates of the plurality of storage compartments, a shortest travelling path or a combination thereof.
13. The method (400) as claimed in claim 10, wherein the compartment identifier corresponds to a compartment machine-readable code; wherein the carton identifier corresponds to a carton machine-readable code; wherein the bin identifier corresponds to a bin machine-readable code; wherein each of the compartment machine-readable code, carton machine-readable code, and bin machine-readable code correspond to one of a linear barcode, radio frequency identification (RFID) tag, quick response (QR) code, optical label, or a combination thereof.
14. The method (400) as claimed in claim 10, wherein the picking operation at the pick zone (202) is performed either automatically through the one or more smart robots (106), or manually by a pick worker.
Dated this 27th day of January 2023