Block Storage Sequencing for Delivery Container Loading
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Solution Overview
Problem
Existing storage arrangements in warehouse layouts, such as high-bay warehouses, face inefficiencies in sequencing goods for delivery containers due to the need for additional buffer storage areas, which increase costs and require complex handling to achieve the correct sequence of goods based on weight and stability, especially when transitioning from horizontal storage to shipping areas.
Innovation Solution
A block storage system with a three-dimensional matrix of stacking areas, where packaging units are arranged in rows and columns, allowing for flexible access and sequencing of goods using loading vehicles that can insert and remove units from below or above, eliminating the need for additional buffer storage by ensuring a unique assignment between position and goods type, and utilizing loading vehicles with integrated lifting mechanisms or coupled drives for efficient transport and sequencing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If goods are transported directly from high-bay warehouse to shipping area, then handling time is reduced, but the ability to achieve correct sequencing (heavy goods at bottom, stable goods at top) cannot be ensured
Solution Approach 1:
The system performs preliminary sequencing actions by assigning goods to specific stacking positions in the block storage area before final retrieval. The control unit calculates optimal stacking positions based on goods characteristics (weight, stability) and retrieves them in a predetermined sequence, ensuring correct ordering is established during storage placement rather than requiring separate sequencing operations later.
2Manufacturing precision
If a buffer station is introduced before the shipping area for temporary storage and sequencing, then sequencing accuracy is improved, but space requirements and device complexity increase
Solution Approach 1:
The patent merges the storage function and sequencing function into a single block storage area. Instead of having separate storage areas and buffer stations, the system uses one integrated block storage area where goods are stacked in predetermined sequences directly. The control unit manages both storage placement and retrieval sequencing, eliminating the need for additional buffer infrastructure.
Solution Approach 2:
The block storage area serves multiple functions simultaneously: it acts as both the primary storage location and the sequencing mechanism. The same stacking areas where goods are stored also determine the retrieval sequence, making the storage system universal for both purposes rather than requiring specialized buffer components.
3Quantity of substance
If traditional high-bay warehouse with storage and retrieval machines is used, then storage capacity is achieved, but access flexibility is limited due to machine availability and obstruction constraints
Solution Approach 1:
The storage area is segmented into multiple independent stacking areas arranged in a matrix, each accessible from below by loading vehicles. This segmentation allows any stacking area to be accessed independently without requiring a single large retrieval machine, enabling flexible access to any position in the storage volume without machine obstruction constraints.
Solution Approach 2:
Instead of accessing goods from above or the side as in traditional high-bay warehouses, the system inverts the access approach by loading and unloading packaging units from below. Loading vehicles drive into the loading area below the block storage area and access stacking areas from underneath, reversing the conventional access direction and enabling greater flexibility.
Data Source
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AI summary
A method for operating a storage arrangement (1) is described, in which goods (4) in a delivery container are introduced into the storage arrangement (1) at a goods receipt (2), removed from the delivery container, temporarily stored, and then removed from the storage arrangement (1) in a delivery container at a goods issue (3) according to a predetermined sequence. The aim is to manufacture and/or operate such a storage arrangement cost-effectively. For this purpose, it is provided that the goods are transferred from the delivery container into a stackable packaging unit (5), and the packaging unit (5) is temporarily stored in a block storage area (7). The block storage area (7) has several stacking spaces (8), and each stacking space (8) is designed to receive a stack of packaging units (5). The goods are removed from the block storage area according to a sequence predetermined by the goods issue.