Buffer Storage Sequencing Using Reciprocating Elevators
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Solution Overview
Problem
Existing buffer storage and sequencing systems for logistics, such as automated storage and removal warehouses, face challenges including excessive footprint, maintenance access difficulties, and limited capacity due to dense conveyor layouts, which hinder efficiency and increase costs.
Innovation Solution
A system utilizing vertically disposed 'first-in first-out' conveyor levels combined with reciprocating elevators for load sequencing, minimizing sequencing constraints at the external unit and optimizing load handling through a management unit that organizes movements between these entities, reducing the footprint and complexity of the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a dense conveyor layout is used in buffer storage systems, then the system can achieve compact footprint, but maintenance access becomes difficult and capacity is limited
Solution Approach 1:
The system divides the buffer storage into multiple independent levels (first level, second level, third level) with separate conveyors for each level. This segmentation allows maintenance personnel to access specific levels without disrupting the entire system, while each level maintains a compact footprint through vertical stacking.
Solution Approach 2:
The patent transitions from a horizontal conveyor layout to a vertical multi-level configuration. By stacking conveyors vertically (first level at bottom, second level above, third level at top), the system achieves compact footprint in the horizontal plane while maintaining accessibility through vertical access points and stairways between levels.
2Area of stationary object
If a dense conveyor layout is used in buffer storage systems, then the system can achieve compact footprint, but the capacity to handle loads is reduced
Solution Approach 1:
The system utilizes vertical space by implementing three stacked levels of conveyors (first, second, and third levels). This vertical arrangement multiplies the effective storage capacity within a compact horizontal footprint, allowing significantly more loads to be accommodated in the buffer storage without increasing the overall area occupied.
Solution Approach 2:
The conveyors are arranged in a nested vertical configuration where the second level conveyor is positioned above the first level, and the third level conveyor is positioned above the second level. This nesting approach maximizes space utilization and increases loading capacity within a compact footprint.
3Productivity
If sequencing constraints are imposed at the external unit, then load sequencing can be controlled, but system complexity and costs increase
Solution Approach 1:
The patent introduces a buffer storage system as an intermediary between the external unit and the preparing station. This buffer receives non-sequenced loads from the external unit, resequences them using the multi-level conveyor system, and delivers sequenced loads to the preparing station. This intermediary approach enables sequencing control without imposing complex constraints on the external unit, thereby reducing overall system complexity.
Solution Approach 2:
The sequencing function is segmented across multiple independent levels (first, second, and third levels), each capable of handling specific portions of the load sequence. This segmentation allows flexible sequencing control while distributing the complexity across independent modules rather than requiring a single complex sequencing mechanism.
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
This solution reduces the size and complexity of the external units, optimizes system efficiency, and allows for handling multiple formats of loads, thereby minimizing costs and enhancing reactivity, while enabling flexible sequencing of loads for preparing stations.
Implementation Method 1
un known configuration for an automated storage system for preparing customer orders comprising: an automated storage/removal warehouse (7) comprising several sets (two in this example) each formed by an alley (7a, 7a') feeding, on either side, a storage shelf (7b, 7c, 7b', 7c') with several superimposed stacking levels
Implementation Method 2
a set of conveyors taking the source loads from the automated warehouse (7) up to the preparing stations and vice versa
Data Source
AI summary
A system for buffer storage and sequencing of items that receives unsequenced items and delivers sequenced items is provided. The system includes: a buffer storage unit having N input levels each having a FIFO conveyor, where N≥2; reciprocating input and output elevators positioned respectively at the input and output of N input levels; and a control unit configured to organize, under a constraint of delivery to at least one forward output conveyor of at least one sequence of items, various movements of items (from at least one forward input conveyor to the reciprocating input elevator, from the reciprocating input elevator to the N input levels, from the N input levels to the reciprocating output elevator, and from the reciprocating output elevator to the at least one forward output conveyor).