Autonomous Storage Retrieval Mixed Pallet Handling

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Solution Overview

Problem

Current material handling systems in warehouses face inefficiencies in transferring items between storage levels, particularly in systems that rely on lifts and vehicles, which limits the rate of item movement and flexibility in handling mixed pallet loads with varying SKUs and dimensions.

Innovation Solution

An automated storage and retrieval system that includes autonomous transport vehicles, lift modules, and a networked control system to manage inventory and pickfaces, enabling efficient sorting, sequencing, and assembly of mixed pallet loads by breaking down uniform pallets into individual case units, sorting, and reassembling them into mixed pallets with a structured architecture for stable and efficient storage and retrieval.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If lifts and vehicles are used to transfer items between storage levels, then items can be moved between different storage levels, but the rate of item transfer is limited and system flexibility is reduced

Engineering Contradiction:

Improverate of item transferVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the storage structure into multiple independently accessible storage levels, each with its own autonomous vehicles. This segmentation eliminates the need for centralized lifts, allowing parallel operations at multiple levels simultaneously, thereby increasing the overall item transfer rate without proportionally increasing system complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Autonomous vehicles are equipped with onboard lifts that enable them to independently transfer between storage levels without requiring external lift assistance. This self-service capability allows vehicles to autonomously service multiple storage levels, significantly improving transfer rates while maintaining manageable system complexity through standardized vehicle designs.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If traditional lifts are used for transfer, then items can be moved between storage levels, but flexibility in handling mixed pallet loads with varying SKUs and dimensions is limited

Engineering Contradiction:

Improveflexibility in handling mixed pallet loadsVSAvoiditem transfer rate

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system employs dynamically configurable pickfaces that can be adjusted to accommodate varying SKU and dimension requirements. Autonomous vehicles can selectively access different pickfaces based on real-time retrieval needs, enabling flexible handling of mixed pallet loads while maintaining high transfer rates through automated, rapid reconfiguration capabilities.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Autonomous vehicles are designed with multi-functional capabilities, including onboard lifts, variable payload configurations, and the ability to service multiple storage levels. This universality allows a single vehicle type to handle diverse pallet load configurations across different storage levels, improving both adaptability and transfer efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Quantity of substance

If items are stored in storage spaces on each storage level accessible by transport vehicles, then storage capacity is increased, but the rate of item transfer remains dependent on vehicle availability

Engineering Contradiction:

Improvestorage capacityVSAvoiditem transfer rate

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The system implements continuous autonomous vehicle circulation between storage levels and pickfaces, eliminating idle waiting time. Vehicles maintain continuous useful action by immediately transitioning between storage and retrieval tasks, ensuring that storage capacity is fully utilized while maximizing item transfer rates through uninterrupted operational cycles.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Autonomous vehicles serve as intermediaries between bulk storage areas and pickfaces, enabling decoupled operations. While vehicles transport items between levels, storage operations can proceed independently, allowing storage capacity to be maximized without bottlenecking the transfer rate, as the vehicle system mediates between storage and retrieval demands.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11787634B2Storage and retrieval system

Publication Date: 2023.10.17 SYMBOTIC LLC

AI summary

In accordance with one or more aspects of the disclosed embodiment, a lift includes at least one load handling device configured so as to reciprocate along a lift axis, the load handling device including a frame forming a payload section with a payload support surface having a common elevation configured to hold one or more pickfaces at the common elevation of the payload support surface, at least one transfer arm movably mounted to the frame, and a drive section connected to the load handling device and being configured to move the load handling device along the lift axis, wherein the one or more pickfaces carried in unison by the payload support surface of the at least one load handling device, define an order sequence of pickfaces on the at least one load handling device according to a predetermined case out order sequence of mixed cases.