Storage Grid Bin Weight Distribution for Taller Stacks
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Solution Overview
Problem
Current storage systems are limited by a maximum weight of 30 kg per storage bin, allowing only 14 bins to be stacked, which restricts the system's capacity and height, and increasing costs to handle heavier loads.
Innovation Solution
A method and system that dynamically adjust storage positions based on the weight of each bin, allowing overloading in some bins and underloading in others within the same column, using weight sensors and a storage control system to manage the distribution and ensure the maximum load is not exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the maximum weight per storage bin is limited to 30 kg, then the storage bin structure can be kept simple and cost-effective, but the system capacity and stack height are restricted to only 14 bins
Solution Approach 1:
The system dynamically adjusts storage assignments based on real-time weight data. The control system receives weight information from sensors, calculates column loads, and dynamically determines optimal storage positions and vehicle assignments, allowing the system to adapt to varying bin weights rather than using fixed weight limits
Solution Approach 2:
Weight sensors provide continuous feedback about storage bin weights to the control system. This feedback loop enables the control system to monitor column loads, track cumulative weights, and make real-time decisions about where to place bins and how to distribute loads, ensuring the maximum load capacity is not exceeded while maximizing system capacity
2Length of stationary object
If more than 14 storage bins are stacked in columns, then the system height and capacity increase, but the maximum load on lowermost bins exceeds the tolerated 30 kg limit
Solution Approach 1:
The system applies different weight distribution strategies to different columns based on their specific load characteristics. By calculating the cumulative weight for each column individually and assigning bins to specific columns based on current load status, the system optimizes weight distribution locally in each column rather than applying a uniform limit across all columns
Solution Approach 2:
The system changes the operational parameter from a fixed per-bin weight limit to a dynamic column-based cumulative weight management approach. By monitoring and adjusting the total load in each column rather than limiting each individual bin uniformly, the system enables taller stacks while maintaining safety within the maximum load tolerance
3Reliability
If uniform weight distribution is enforced across all columns, then structural safety is maintained, but system productivity and storage efficiency decrease
Solution Approach 1:
The control system performs preliminary calculations of column loads and optimal bin placements before actual storage operations. By pre-determining which columns have available capacity and planning the weight distribution in advance, the system ensures structural safety is maintained while optimizing storage efficiency and avoiding last-minute adjustments that would reduce productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables storage of bins with weights exceeding 30 kg without reducing stack height, allowing more than 14 bins to be stacked, and increasing the system's capacity without significant cost increases, by optimizing bin loading within existing infrastructure.
Implementation Method 1
a weight estimation device, in particular a weight sensor (70), for estimating the weight of storage bins (2)
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2f
AI summary
The present invention relates to a method for storing product items (80) in storage bins (2) in a storage system (3) comprising a bin storing grid (15) in which storage bins (2) are stored above each other in columns (8). The method comprises transporting the storage bin (2) between the bin storing grid (15) and a port (60) by means of a vehicle (1) and a bin lift device (4) provided on each vehicle (1). The method comprises determining a weight (w) for each storage bin (2) after one or more product items (80) have been inserted to or retrieved from the storage bin (2). The method comprises determining a storage position (p) for the storage bin (2) in the bin storing grid (15) based on the weight (w). The present invention also relates to a storage system (3) for storing product items (80) in storage bins (2).