Angled Rack Elements for AS/RS Spatial Footprint Reduction
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Solution Overview
Problem
Automated storage and retrieval systems (AS/RS) face challenges in efficiently configuring multiple racks to minimize spatial footprint while enabling effective storage and retrieval operations across multiple aisles.
Innovation Solution
The implementation of an angled rack element positioned between parallel aisles, which utilizes gravitational forces to facilitate the movement of objects from one shuttle to another, allowing for unidirectional transportation and efficient retrieval operations by configuring a conveyance surface with rollers or a conveyor belt, enabling objects to be moved along a transportation path and loaded onto a second shuttle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional horizontal rack configurations are used, then ease of operation and manufacturing are improved, but spatial footprint and area requirements increase
Solution Approach 1:
The patent applies dimensionality change by transitioning from traditional horizontal rack arrangements to a three-dimensional configuration where racks are positioned at angled orientations (e.g., 45 degrees) relative to aisles. This angular positioning allows racks to extend into the vertical and lateral dimensions more efficiently, reducing the overall floor space required while maintaining accessibility. The angled racks create a compact spatial arrangement that utilizes volume rather than just horizontal area.
Solution Approach 2:
The patent implements nesting by positioning multiple racks in a hierarchical arrangement where smaller racks are placed within the spatial envelope created by larger rack structures. The angled configuration allows racks to be nested closer together, with inner racks accessible through aisles formed by outer racks, creating a space-efficient nested layout that minimizes the external footprint while maximizing storage capacity.
2Area of stationary object
If angled rack elements are used, then spatial footprint is reduced, but device complexity and operational difficulty increase
Solution Approach 1:
The patent applies segmentation by dividing the rack system into modular, standardized angled units that can be independently manufactured and assembled. Each rack segment is designed with standard angles (e.g., 45 degrees) and consistent dimensions, allowing complex angled configurations to be built from simple, repeatable modules. This segmentation reduces overall structural complexity by breaking down the challenging angled geometry into manageable, pre-fabricated components.
Solution Approach 2:
The patent utilizes composite construction methods where rack elements combine different materials and structural features to simplify the overall design. By using composite rack structures that integrate support, storage, and positioning functions into unified components, the system reduces the number of separate parts and assembly steps required, thereby lowering device complexity despite the angled configuration.
3Productivity
If angled rack elements with gravitational movement are used, then productivity and automation are improved, but device complexity increases
Solution Approach 1:
The patent applies self-service by designing the angled rack system to automatically transport objects using gravitational forces. Objects placed on the angled racks naturally slide or roll along the incline toward designated retrieval points without requiring external power sources, motors, or active control mechanisms. This passive gravitational conveyance system achieves automated object movement while minimizing the complexity of mechanical drive systems.
Solution Approach 2:
The patent replaces complex mechanical conveyor systems with a simpler gravitational flow mechanism. Instead of using motors, belts, or powered rollers to move objects, the system uses the angle of the racks themselves to convert gravitational potential energy into kinetic energy, causing objects to move automatically. This substitution eliminates the need for complex powered mechanical transmission systems while maintaining productive object transportation.
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 configuration reduces the spatial requirements of the system, enhances operational efficiency by allowing simultaneous handling of multiple objects, and automates the retrieval process without manual intervention, thereby optimizing storage and retrieval operations within a minimized footprint.
Implementation Method 1
the angled rack element may be configured to utilize the one or more gravitational forces to facilitate transportation of the one or more object from the first shuttle to the second shuttle
Data Source
AI summary
Various embodiments are directed to an automated storage and retrieval system and methods of using the same. In various embodiments, an AS/RS comprises an angled rack element provided in between a first aisle and a second aisle, wherein a first end of the angled rack element is positioned adjacent the first aisle and a second end of the angled rack element is positioned adjacent the second aisle, and wherein the angled rack element is configured to receive an object dispensed from a first shuttle positioned within the first aisle; wherein the angled rack element defines a pitch angle defined relative to a horizontal plane to facilitate movement of the object disposed on a conveyance surface along a unidirectional transportation path towards the second end; and wherein the angled rack element is configured such that the object at the loading position is accessible to the second shuttle via the second aisle.