Autonomous Multilevel Case-Unit Storage for Individual Retrieval
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Solution Overview
Problem
Conventional warehousing systems, including automated systems, are inefficient in generating mixed goods pallets and do not allow for the retrieval of individual case units without transporting the entire carrier or pallet to a workstation.
Innovation Solution
A storage and retrieval system with multilevel vertical conveyors and autonomous transport robots that enable the direct storage and retrieval of individual case units without containers, using bots to transfer case units between storage spaces and conveyors, and a control system for inventory management and order fulfillment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If case units are stored in carriers or on pallets, then storage density is improved, but retrieval of individual case units requires transporting the entire carrier or pallet
Solution Approach 1:
The system segments the storage and retrieval process by allowing individual case units to be stored separately in designated spaces within the rack structure, rather than grouping them in carriers or on pallets. This enables the retrieval of single case units without moving other units, directly resolving the contradiction between storage density and retrieval efficiency.
Solution Approach 2:
The patent introduces an intermediary mechanism (the robotic system with grippers) that can selectively grasp and manipulate individual case units. This intermediary enables precise handling of single units without requiring movement of entire carriers or pallets, thus improving retrieval time while maintaining storage density.
2Extent of automation
If conventional automated warehousing systems are used, then automation level is improved, but efficiency in generating mixed goods pallets deteriorates
Solution Approach 1:
The system employs dynamic robot navigation and adaptive path planning that allows autonomous vehicles to efficiently navigate the rack structure and retrieve case units in optimal sequences for assembling mixed goods pallets. This dynamic approach enables high-speed retrieval of diverse products without the constraints of fixed automated conveyor paths, thereby improving mixed goods pallet generation efficiency while maintaining high automation levels.
Solution Approach 2:
The autonomous vehicles perform self-navigation and self-manipulation of case units without human intervention. The system autonomously determines retrieval sequences, navigates to appropriate locations, grasps case units, and delivers them to pallet assembly points, enabling self-service operation that efficiently generates mixed goods pallets with high automation.
3Adaptability or versatility
If individual case units are retrieved without containment, then handling flexibility is improved, but system complexity increases
Solution Approach 1:
The patent replaces complex mechanical containment structures (carriers, pallets) with a robotic manipulation system that uses controlled gripping forces to handle individual case units. The robotic grippers apply precise mechanical forces to grasp and transport single units without containment, providing handling flexibility while the control system manages the complexity through software rather than mechanical design.
Data Source
AI summary
A storage and retrieval system including a vertical array of storage levels, each storage level having, picking aisles, storage locations, disposed within the picking aisles, and at least one transfer deck providing access to the picking aisles, a multilevel vertical conveyor system configured to transport the uncontained case units to and from the vertical array of storage levels, each storage level being configured to receive uncontained case units from the multilevel vertical conveyor system, at least one autonomous transport located on each storage level for transporting the uncontained case units between respective storage locations and the multilevel vertical conveyor system, and a controller configured to create a primary access path through the transfer decks and picking aisles to a predetermined one of the storage locations and at least one secondary access path to the predetermined one of the storage locations when the primary path is impassable.