3D Robotic Storage Retrieval for Direct, Hand-Off-Free Conveyance
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Solution Overview
Problem
Existing automated storage and retrieval systems face inefficiencies in the conveyance of storage units between storage locations and working stations, often requiring hand-offs to conveyors or handlers, which can disrupt the flow and increase complexity.
Innovation Solution
A three-dimensional storage system utilizing robotic vehicles that travel in three dimensions, enabling direct conveyance of storage units between storage locations and working stations without intermediate hand-offs, using sensors for alignment and navigation, and incorporating lifting mechanisms for vertical transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hand-offs to conveyors or handlers are used for transferring storage units, then the system can handle complex transfer scenarios, but the operational flow is disrupted and system complexity increases
Solution Approach 1:
The robotic vehicle integrates multiple functions into a single unit: it serves as both the storage unit carrier and the transfer mechanism between storage locations and working stations. The vehicle combines navigation, lifting, and precise positioning capabilities, eliminating the need for separate conveyor systems and manual handlers, thereby maintaining operational flow continuity while handling complex transfer scenarios
Solution Approach 2:
The robotic vehicle acts as an intelligent intermediary between storage locations and working stations. It autonomously navigates the three-dimensional space, coordinates vertical transitions through lifting mechanisms, and delivers storage units directly to designated working stations, replacing the traditional multi-component transfer system with a single coordinated agent
2Adaptability or versatility
If multiple intermediate hand-offs are used for storage unit conveyance, then transfer flexibility is improved, but system complexity and operational disruptions increase
Solution Approach 1:
The robotic vehicle is designed as a universal platform that can perform multiple functions: transporting storage units horizontally across the facility, vertically between floors via lifting mechanisms, and precisely positioning units at working stations. This multi-functional design replaces the need for multiple specialized components (conveyors, elevators, handlers) with a single versatile robotic system
Solution Approach 2:
The system transitions from two-dimensional horizontal conveyor-based transfer to three-dimensional space utilization. The robotic vehicle navigates across multiple levels and floors, using vertical lifting mechanisms to access storage units at different heights, thereby adding the vertical dimension to the transfer operation and eliminating the need for complex horizontal conveyor networks
3Productivity
If direct conveyance by robotic vehicles is used, then operational flow continuity is improved, but navigation and positioning precision requirements increase
Solution Approach 1:
The robotic vehicle incorporates sensors and navigation systems that continuously monitor its position, orientation, and the position of storage units. Real-time feedback from these sensors allows the vehicle to make precise adjustments to its navigation and positioning, ensuring accurate delivery to working stations while maintaining operational flow continuity
Solution Approach 2:
The system replaces traditional mechanical positioning mechanisms with sensor-based navigation and control systems. Optical sensors, cameras, and other detection devices monitor the vehicle's position and the storage unit's location, using electronic control to achieve precise positioning without complex mechanical adjustment mechanisms
Data Source
AI summary
An improved storage and retrieval system employing a gridded three-dimensional storage structure features workstations served by the same robotic vehicle fleet that serves the storage structure, travel-through workstations using the same robotic vehicles to carry storage units through the workstation without hand-off to any other conveyor or handler, internal sortation using orchestrated navigation of the robotic vehicles to workstation intake points, sensors on the robotic vehicles to confirm proper loading and alignment of storage units thereon, lifting mechanisms for raising the robotic vehicles into shafts of the grid from a lower track thereof, use of markers and scanners to align the robotic vehicles with the grid shafts, and workstation light curtains for hand safety, pick-counting and container content protrusion detection.