Robotized Warehouse Systems: Developments and Research Opportunities

Robotized handling systems are increasingly applied in distribution centers. They require little space, provide flexibility in managing varying demand requirements, and are able to work 24/7. This makes them particularly fit for e-commerce operations. This paper reviews new categories of robotized handling systems, such as the shuttle-based storage and retrieval systems, shuttle-based compact storage systems, and robotic mobile fulfillment systems. For each system, we categorize the literature in three groups: system analysis, design optimization, and operations planning and control. Our focus is to identify the research issue and OR modeling methodology adopted to analyze the problem. We find that many new robotic systems and applications have hardly been studied in academic literature, despite their increasing use in practice. Due to unique system features (such as autonomous control, networked and dynamic operation), new models and methods are needed to address the design and operational control challenges for such systems, in particular, for the integration of subsystems. Integrated robotized warehouse systems will form the next category of warehouses. All vital warehouse design, planning and control logic such as methods to design layout, storage and order picking system selection, storage slotting, order batching, picker routing, and picker to order assignment will have to be revisited for new robotized warehouses

Performance evaluation of shuttle-based storage and retrieval systems using discrete-time queueing network models

Shuttle-based storage and retrieval systems (SBS/RSs) are an important part of today‘s warehouses. In this work, a new approach is developed that can be applied to model different configurations of SBS/RSs. The approach is based on the modeling of SBS/RSs as discrete-time open queueing networks and yields the complete probability distributions of the performance measures

Performance evaluation of warehouses with automated storage and retrieval technologies.

In this dissertation, we study the performance evaluation of two automated warehouse material handling (MH) technologies - automated storage/retrieval system (AS/RS) and autonomous vehicle storage/retrieval system (AVS/RS). AS/RS is a traditional automated warehouse MH technology and has been used for more than five decades. AVS/RS is a relatively new automated warehouse MH technology and an alternative to AS/RS. There are two possible configurations of AVS/RS: AVS/RS with tier-captive vehicles and AVS/RS with tier-to-tier vehicles. We model the AS/RS and both configurations of the AVS/RS as queueing networks. We analyze and develop approximate algorithms for these network models and use them to estimate performance of the two automated warehouse MH technologies. Chapter 2 contains two parts. The first part is a brief review of existing papers about AS/RS and AVS/RS. The second part is a methodological review of queueing network theory, which serves as a building block for our study. In Chapter 3, we model AS/RSs and AVS/RSs with tier-captive vehicles as open queueing networks (OQNs). We show how to analyze OQNs and estimate related performance measures. We then apply an existing OQN analyzer to compare the two MH technologies and answer various design questions. In Chapter 4 and Chapter 5, we present some efficient algorithms to solve SOQN. We show how to model AVS/RSs with tier-to-tier vehicles as SOQNs and evaluate performance of these designs in Chapter 6. AVS/RS is a relatively new automated warehouse design technology. Hence, there are few efficient analytical tools to evaluate performance measures of this technology. We developed some efficient algorithms based on SOQN to quickly and effectively evaluate performance of AVS/RS. Additionally, we present a tool that helps a warehouse designer during the concepting stage to determine the type of MH technology to use, analyze numerous alternate warehouse configurations and select one of these for final implementation

Simulation model used as design improvement decision tool for warehouse material flow

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2005.Includes bibliographical references (p. 109-110).The basis for this thesis involved a six and a half month LFM internship at Efficient Storage, Shipping, and Selection. ES3, Efficient Storage, Shipping, and Selection, is a third party logistics firm that specializes in a vendor-neutral consolidation model for the food distribution industry. ES3 receives, stores, and ships multi-vendor products through a distribution center (DC) in York, Pennsylvania. The product is moved and stored by an Automated Storage and Retrieval System (ASRS) which consists of a network of conveyors, vertical lifts, and Selection and Retrieval Machines (SRMs). The ASRS system is not performing to the designed put-away and shipping rates, thus limiting the DC's overall performance during peak operations. The warehouse operations and warehouse design teams had numerous design suggestions for improving the ASRS operations, but it was difficult to predict the enhancement or impact on performance. A simulation model for the inbound system was created to analyze the impact, prioritize, and develop new ideas for improving the system.by Clifford A. Smith.S.M.M.B.A

Modelling of a rope-free passenger transportation system for active cabin vibration damping

Conventional vertical passenger transportation is performed by lifts. Conventional traction-drive electrical lifts use ropes to transfer the rotational motion of an electrical motor into a vertical motion of the cabin. The vertical passenger transportation system discussed in this paper does not use any ropes, the motor directly provides a driving force, which moves the cabin. This new propulsion is realized through an electrical linear motor. The use of the linear motor requires a new design of the passenger transportation system (PTS), which includes reducing the weight of the car through lightweight construction. The reduced stiffness of the lightweight design renders the construction more vulnerable to vibrations. In order to improve ride quality of the transportation system it is necessary to develop new concepts to damp the vibrations. One way to increase stiffness characteristics of the system is to introduce active damping components to be used alongside passive damping components. It is essential to derive a dynamic model of the system in order to design and also later control these damping components in the best possible way. This paper describes the fundamental steps undertaken to derive a dynamic model for designing and controlling active damping components for the new type of vertical PTS. The model is derived as a Multi-Body System (MBS), where the connections between the bodies are modelled as spring damper elements. The derivation of the MBS is demonstrated on a transportation system, consisting of three main components: a sledge, holding the rotor of the linear motor; a mounting frame, which is used to provide support for the cabin; and the actual cabin. The modelling of the propulsion system, thus the electrical part of the PTS, will not be the focus of this work

Evaluating a holistic energy benchmarking parameter of lift systems by using computer simulation

At present, there are benchmarking parameters to assess the energy performance of lifts, e.g. one in Germany adopted by VDI (4707-1/2), one internationally published by ISO (BS EN ISO 25745-2:2015), and the other in Hong Kong adopted by The Hong Kong Special Administrative Region (HKSAR) Government. These parameters are mainly checking the energy consumed by a lift drive without considering real time passenger demands and traffic conditions; the one in Hong Kong pinpointing a fully loaded up-journey under rated speed and the two in Europe pinpointing a round trip, bottom floor to top floor and return with an empty car, though including energy consumed by lighting, displays, ventilation etc. A holistic normalization method by Lam et al [1] was developed a number of years ago by one of the co-authors of this article, which can assess both drive efficiency and traffic control, termed J/kg-m, which is now adopted by the HKSAR Government as a good practice, but not specified in the mandatory code. In Europe, the energy unit of Wh has been used but here, Joule (J), i.e. Ws, is adopted to discriminate the difference between the two concepts. In this article, this parameter is evaluated under different lift traffic scenarios using computer simulation techniques, with an aim of arriving at a reasonable figure for benchmarking an energy efficient lift system with both an efficient drive as well as an efficient supervisory traffic control

A study into the influence of the car geometry on the aerodynamic transient effects arising in a high rise lift installation

One of the main goals in designing a high-speed lift system is developing a more aerodynamically efficient car geometry that guarantees a good ride comfort and reduces the energy consumption. In this study, a three-dimensional computational fluid dynamics (CFD) model has been developed to analyse an unsteady turbulent air flow around two cars moving in a lift shaft. The paper is focused on transient aerodynamic effects arising when two cars pass each other in the same shaft at the same speed. The scenarios considered in the paper involve cars having three different geometries. Aerodynamic forces such as the drag force that occur due to the vertical opposite motions of the cars have been investigated. Attention is paid to the airflow velocity and pressure distribution around the car structures. The flow pattern in the boundary layer around each car has been calculated explicitly to examine the flow separation in the wake region. The results presented in the paper would be useful to guide the lift designers to understand and mitigate the aerodynamic effects arising in the lift shaft

Applications of Genetic Algorithm and Its Variants in Rail Vehicle Systems: A Bibliometric Analysis and Comprehensive Review

Railway systems are time-varying and complex systems with nonlinear behaviors that require effective optimization techniques to achieve optimal performance. Evolutionary algorithms methods have emerged as a popular optimization technique in recent years due to their ability to handle complex, multi-objective issues of such systems. In this context, genetic algorithm (GA) as one of the powerful optimization techniques has been extensively used in the railway sector, and applied to various problems such as scheduling, routing, forecasting, design, maintenance, and allocation. This paper presents a review of the applications of GAs and their variants in the railway domain together with bibliometric analysis. The paper covers highly cited and recent studies that have employed GAs in the railway sector and discuss the challenges and opportunities of using GAs in railway optimization problems. Meanwhile, the most popular hybrid GAs as the combination of GA and other evolutionary algorithms methods such as particle swarm optimization (PSO), ant colony optimization (ACO), neural network (NN), fuzzy-logic control, etc with their dedicated application in the railway domain are discussed too. More than 250 publications are listed and classified to provide a comprehensive analysis and road map for experts and researchers in the field helping them to identify research gaps and opportunities

Travel Time Models and Throughput Analysis of Dual Load Handling Automated Storage and Retrieval Systems in Double Deep Storage

A general analytical travel time model for the quadruple command cycle in double deep storage systems with a dual capacity load handling device is formulated and validated by means of a simulation model. Various routing and sequencing strategies are composed. A simulation model is used to compare strategies for differnt AS/RS configurations and settings to assess them in consideration of real-world cases. For selected strategies, analytical formulations are derived