ASRS Control Architecture for Throughput and Storage Density
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Solution Overview
Problem
Automated storage and retrieval systems (ASRS) in warehouses and stores face inefficiencies due to the trade-off between storage space efficiency and transport efficiency, where optimizing one factor often detracts from the other, leading to minimal overall efficiency gains.
Innovation Solution
A control system with separate and distinct controllers manages storage and transport operations independently, using autonomous vehicles and dynamic storage location allocation to optimize storage and retrieval processes, allowing for decoupled planning and control of storage and retrieval systems to enhance throughput performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dynamic allocation of storage locations and autonomous vehicles is used to increase storage throughput, then productivity is improved, but device complexity increases
Solution Approach 1:
The control system is divided into multiple independent controllers, each managing specific storage locations or zones. This segmentation allows autonomous vehicles to receive targeted navigation instructions without requiring a monolithic complex control system, thereby improving productivity while managing device complexity through modular architecture.
Solution Approach 2:
The system implements dynamic allocation of storage locations and autonomous vehicles based on real-time demand and vehicle availability. Storage locations are dynamically assigned to different SKUs, and autonomous vehicles are dynamically routed to optimize throughput, allowing the system to adapt to changing conditions without requiring permanent complex infrastructure.
2Productivity
If greater transport speeds and freedom of movement of rovers are implemented, then productivity is improved, but reliability deteriorates
Solution Approach 1:
The control system continuously monitors the position, status, and performance of autonomous vehicles through feedback mechanisms. This real-time feedback allows the system to maintain high transport speeds while detecting and correcting potential failures, thereby preserving reliability even as productivity increases through faster movement.
Solution Approach 2:
Autonomous vehicles are equipped with self-navigation and self-management capabilities, allowing them to independently handle transport tasks without constant human intervention. This self-service approach enables faster transport speeds while maintaining reliability through automated error detection and correction built into the vehicles themselves.
3Quantity of substance
If more storage levels or closely spaced levels are added to increase storage density, then storage space efficiency is improved, but device complexity increases
Solution Approach 1:
The control system serves multiple storage levels and zones through a unified multi-functional platform. Rather than requiring separate control systems for each storage level, the same control architecture manages all levels, reducing device complexity while enabling increased storage density through additional closely spaced levels.
Solution Approach 2:
The system utilizes vertical dimension by implementing multiple storage levels stacked vertically with closely spaced configurations. This dimensional approach increases storage density without proportionally increasing horizontal complexity, as the same control mechanisms are applied vertically across multiple levels rather than requiring expanded horizontal infrastructure.
Data Source
AI summary
An automated storage and retrieval system includes a storage space with locations defined therein, an automated transport system connected to the storage space and configured to transport store units for storage in the storage locations and retrieval from the storage locations, and a control system disposed for managing throughput performance of the automated storage and retrieval system, the control system being operably coupled to the automated transport system and having more than one separate and distinct control sections each configured for managing throughput performance with respect to a common group of the storage locations, wherein at least one of the control sections manages aspects of throughput performance of the common group independent of another of the control sections.