Autonomous Transport Vehicle With On-the-Fly Payload Sortation
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Solution Overview
Problem
Existing storage and retrieval systems face limitations in throughput due to constraints in the retrieval of goods at storage levels and transfer between levels, which can be addressed by integrating payload handling and sorting capabilities on transport vehicles.
Innovation Solution
The system incorporates autonomous transport vehicles with combined movement and sorting capabilities, utilizing a payload section with a pusher bar and transfer arm that allows simultaneous manipulation of multiple items, including a pusher bar that operates independently of the transfer arm's lift and extension axes, enhancing throughput and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate systems are used for transport and sorting, then device complexity is reduced, but productivity decreases due to sequential operations
Solution Approach 1:
The patent combines the transfer arm and pusher bar into a single integrated payload handling system on the autonomous vehicle. The transfer arm moves payloads between storage locations, while the pusher bar performs sorting operations within the payload section. This merging of transport and sorting functions into one vehicle system eliminates sequential operations and increases throughput without requiring separate dedicated systems for each function.
Solution Approach 2:
The autonomous vehicle is designed with multi-functional capabilities, serving both as a transport vehicle for moving payloads between storage locations and as a sorting vehicle using the pusher bar mechanism. This universal design allows a single vehicle to perform multiple operations that would traditionally require separate specialized vehicles, thereby improving productivity while managing device complexity.
2Adaptability or versatility
If independent pusher bar and transfer arm are used, then payload handling flexibility is improved, but device complexity increases
Solution Approach 1:
The payload handling system is segmented into two independent but coordinated components: the transfer arm and the pusher bar. The transfer arm operates independently to move payloads between different storage locations, while the pusher bar operates independently to sort payloads within the payload section. This segmentation allows each component to be optimized for its specific function while maintaining overall system flexibility.
Solution Approach 2:
The system employs dynamic coordination between the transfer arm and pusher bar, where both components can operate simultaneously or sequentially based on operational requirements. The independent operation of each component allows for adaptive payload handling, where the transfer arm can position payloads while the pusher bar sorts them, or vice versa, depending on the task at hand.
3Productivity
If simultaneous manipulation of multiple items is enabled, then productivity increases, but device complexity increases
Solution Approach 1:
The system enables continuous payload handling operations by allowing the transfer arm and pusher bar to operate simultaneously. While the transfer arm is moving a payload from one storage location to another, the pusher bar can be sorting other payloads within the payload section. This continuous operation eliminates idle time and maximizes throughput, as both components perform useful work concurrently rather than sequentially.
Data Source
AI summary
An autonomous transport vehicle includes a frame forming a payload section configured to hold one or more pickfaces, a transfer arm movably mounted to the frame, a drive section connected to the frame, and a controller connected to the drive section, the controller being configured to effect an on-the-fly sortation of pickfaces carried by the autonomous transport vehicle according to a predetermined case out order sequence where the controller commands the drive section so that two or more pickfaces are picked from one or more first case unit holding locations and placed at one or more different second case unit holding locations according to the predetermined case out order sequence.