Automated Battery Swap Loader for ASRS Charging Rack Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated storage and retrieval systems face inefficiencies due to the need for frequent recharging of container handling vehicles, leading to reduced operational cycles and complex, service-intensive charging systems that occupy valuable space and are prone to failure.
Innovation Solution
An automated storage and retrieval system with a modular charging rack and an automated loader that allows for flexible battery exchange at any grid location, reducing the need for cabling and enabling easy movement of vehicles during failures, while improving fire protection and stability through dedicated areas and sprinkler systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional charging systems with cabling and charging stations are used, then vehicles can be recharged, but the system occupies valuable space and is prone to failure requiring frequent service
Solution Approach 1:
The patent extracts the power supply from the vehicle and places it in external storage racks. The vehicle's power compartment can quickly swap with pre-charged power supplies from the racks, eliminating the need for complex cabling and charging stations. This extraction of the charging function from the vehicle itself resolves the contradiction by simplifying the charging system while maintaining reliability through pre-charged backup power supplies.
Solution Approach 2:
The patent implements preliminary action by pre-charging power supplies in external racks before they are needed. Multiple power supplies are kept charged and ready in the racks, so when a vehicle needs power, it can immediately swap to a pre-charged unit without waiting for charging. This eliminates service interruptions and improves reliability while avoiding the need for complex on-site charging infrastructure.
2Productivity
If frequent recharging is required to maintain operation, then vehicles can continue working, but operational cycles are reduced and efficiency decreases
Solution Approach 1:
The system performs preliminary charging of multiple power supplies in external racks before they are needed. When a vehicle's power supply needs replacement, pre-charged units are already available in the racks, allowing immediate swap without waiting for charging. This eliminates recharging wait time and maintains continuous operational cycles, directly resolving the contradiction between productivity and time loss.
Solution Approach 2:
The patent implements a discard and recover system where depleted power supplies are quickly swapped out and replaced with pre-charged units. The depleted supplies are then recovered and recharged in the external racks during non-operational periods. This separation of charging operations from operational periods eliminates recharging time loss during productive cycles while maintaining high productivity.
3Area of stationary object
If charging stations with cabling are used, then vehicles can be recharged, but valuable space is occupied and fire protection becomes more difficult
Solution Approach 1:
The patent extracts the charging function from within the vehicle and relocates it to external racks positioned at a distance. The power supplies are stored in fire-resistant racks separate from the vehicles, eliminating the need for cabling and charging stations in close proximity to vehicles. This resolves the contradiction by reducing the charging area space occupied near vehicles while improving safety through physical separation and dedicated fire protection for the racks.
Solution Approach 2:
The external power supply racks act as an intermediary between the power source and the vehicles. Instead of direct cabling from charging stations to vehicles, the racks serve as a buffer zone with dedicated fire protection. This intermediary structure reduces the space and safety concerns associated with traditional charging infrastructure while maintaining the ability to quickly replace power supplies.
Data Source
AI summary
An automated storage and retrieval system includes at least one container handling vehicle, a horizontal rail system for the container handling vehicle to run on, and a charging station for recharging a replaceable power source of the container handling vehicle. The container handling vehicle includes a power supply compartment for accommodating a replaceable power supply when the container handling vehicle is in use. The charging station includes one or more charging racks. Each charging rack provides a column of charging positions for recharging replaceable power supplies and each charging position is configured to accommodate a replaceable power supply during a recharging process. The charging station includes an automated loader including a power supply support. The automated loader is arranged to move vertically and horizontally for exchanging and transporting a replaceable power supply between the charging rack and the power supply compartment of the container handling vehicle.