Automated Storage Shuttle System Reducing Transfer Car Complexity
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Solution Overview
Problem
Automated storage systems are costly to establish and operate due to the high number of transfer cars required for efficient operation, which increases the overall expense and complexity.
Innovation Solution
The introduction of a shuttle system that operates independently in store aisles, reducing the need for transfer cars by allowing pallets to be moved between tiers and across store blocks, utilizing a combination of parent cars, transfer cars, and shuttles to enhance efficiency and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If transfer cars are used to move pallets between store positions and parent cars in each store aisle, then the handling capacity and efficiency of the storage system is improved, but the number of transfer cars required increases significantly, leading to higher establishment and operating costs
Solution Approach 1:
The transfer car is designed to operate across multiple store blocks on a common rail system, serving multiple store aisles sequentially. A single transfer car can transfer pallets between parent cars in different store blocks, replacing the need for dedicated transfer cars in each store aisle. This multi-functional design maintains high handling capacity while significantly reducing the total number of transfer cars required in the system.
Solution Approach 2:
The system merges the functions of multiple transfer cars into a single shared transfer car that operates on a common rail infrastructure spanning multiple store blocks. By combining resources and creating a shared transportation network, the system achieves the same pallet transfer capacity with fewer vehicles, thereby reducing establishment costs, operating expenses, and system complexity.
2Ease of operation
If dedicated transfer cars are deployed in each store aisle to ensure independent operation and high efficiency, then the operational flexibility and speed of pallet transfer is improved, but the overall system cost increases due to the considerable number of transfer cars required
Solution Approach 1:
The transfer car system is designed to be dynamic and adaptable, capable of serving different store aisles and parent cars in sequence based on operational demand. The shared transfer car can dynamically allocate its capacity to different store blocks as needed, maintaining operational flexibility without requiring dedicated vehicles for each aisle. This dynamic resource allocation preserves ease of operation while reducing the total number of transfer cars.
Data Source
AI summary
A system for an automated storage includes store blocks, in each of which store blocks there is at least one transverse aisle extending through the store block. In addition, in a store block there are several store aisles diverging from the transverse aisle. The system includes, in each store block, at least one parent car arranged to operate in the transverse aisle of the store block. In addition, the system includes one or more transfer cars arranged to operate across the store blocks on the store aisles arranged end-to-end in the parallel store blocks. The system further includes at least one shuttle arranged to operate in the store aisles.