A deep reinforcement learning approach for online and concurrent 3D bin packing optimisation with bin replacement strategies

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In the realm of robotic palletisation, the quest for optimal space utilization remains vital but also presents a critical challenge, particularly due to the constraints of decision complexity and the need for real-time decision-making without complete prior information. The widely adopted rule-based heuristics approaches were ease to use, but failed to adapt dynamically to the complex and changing landscape of online 3D bin packing. This study is motivated by the need for a system that is both more agile and intelligent, capable of managing the intricacies of dual-bin scenarios and the variable inflow of items. This study introduces a novel deep reinforcement learning (DRL) optimiser, employing a double deep Q-network (DDQN) to obtain optimal packing policies in an online environment with two proposed bin replacement strategies. This approach surpasses the limitations of previous methods by facilitating the simultaneous management of multiple bins and enabling on-the-fly adjustments to decisions based on limited prior knowledge. In a case study involving a logistics company, the proposed optimizer demonstrated a significant improvement in average space utilization across various lookahead scenarios, outperforming traditional heuristics in simulation experiments. The proposed optimiser contributes significantly to the economic and environmental sustainability of robotic warehouses, positioning itself as a cornerstone for the future of smart logistics.