Chessboard Conveyor Level for Warehouse Storage Bottlenecks
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Solution Overview
Problem
Conventional storage and picking systems face inefficiencies due to bottlenecks in material flow, limited flexibility in sequencing, and challenges in maintaining and accessing conveyor systems, particularly in the pre-zone, which affects throughput and warehouse layout compactness.
Innovation Solution
The introduction of a chessboard-like conveyor level that allows for a large number of freely assignable vertical conveyors, enabling dynamic routing and eliminating the need for fixed sequencing stages, with a material flow computer managing routes and optimizing distribution across a flexible network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a classic pre-zone with continuous conveyors and sorters is used, then articles can be transported in a structured manner, but the system creates bottlenecks in material flow and reduces throughput
Solution Approach 1:
The patent removes the sorting carousel and continuous conveyor technology from the pre-zone, extracting the bottleneck elements from the system. Articles are transported directly from vertical conveyors to target points via AGVs, eliminating the need for intermediate sorting infrastructure and enabling parallel material flow paths.
Solution Approach 2:
The system replaces fixed conveyor routes with dynamic AGV-based transport. The material flow paths are no longer static but can be dynamically assigned and reconfigured based on current picking requirements, allowing flexible optimization of throughput without physical reconfiguration.
2Adaptability or versatility
If buffer sections and sorting carousels are added to the pre-zone, then article sequencing capability is improved, but the available space is reduced and maintenance access becomes difficult
Solution Approach 1:
The patent relocates the pre-zone from a horizontal plane in front of the warehouse to a vertical dimension by positioning it above the rack arrangement. This dimensional shift creates sufficient space for sequencing operations without expanding the horizontal footprint, and improves accessibility for maintenance from above.
Solution Approach 2:
The AGV fleet serves multiple functions: transporting articles from vertical conveyors to target points, performing sequencing operations through dynamic route assignment, and replacing the need for dedicated buffer sections and sorting carousels. This multi-functional approach achieves sequencing flexibility without requiring additional specialized infrastructure.
3Manufacturing precision
If multiple sequencing stages are implemented, then article ordering accuracy is improved, but the planning and control effort increases significantly
Solution Approach 1:
The patent combines the sequencing function with the transport function by using AGVs to perform both operations simultaneously. Instead of separate sequencing stages, the material flow computer dynamically assigns routes that achieve both transportation and ordering in a unified process, reducing control complexity while maintaining sequencing accuracy.
Solution Approach 2:
The AGVs autonomously perform sequencing operations based on dynamic route assignment from the material flow computer. The system self-regulates the sequencing process through intelligent dispatching rather than requiring complex multi-stage control mechanisms, simplifying the overall control architecture.
4Reliability
If fixed route conveyors are used in the pre-zone, then system reliability is improved, but the adaptability to changing picking requirements is reduced
Solution Approach 1:
The patent replaces static conveyor routes with dynamic AGV navigation. Routes are determined in real-time based on current picking orders, vertical conveyor locations, and target point requirements. This dynamic approach provides both reliability through systematic route planning and adaptability through flexible reconfiguration without physical modifications.
Data Source
Figure 1
Figure 2A~2B
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AI summary
The invention discloses a storage and picking system for the storage and retrieval of a multiplicity of articles, having a statically arranged rack arrangement, which has a multiplicity of racks (16), wherein the racks (16) each have a multiplicity of rack locations (R), which are arranged one above the other and one beside the other and in which the articles can be stored, and from which they can be retrieved, wherein the racks (16) define at least one aisle (18) between them; having a multiplicity of statically arranged vertical conveyors (20), wherein, in order for the aisles (18) to be connected up for material-flow purposes, in each case a plurality of vertical conveyors (20) either are adjacent laterally to longitudinal sides of the corresponding racks (16) or are arranged within the corresponding racks (16), and wherein the vertical conveyors (20) transport the articles substantially vertically; having a multiplicity of transfer locations (T), which are arranged in the rack arrangement (14) for material-flow-related uncoupling between the vertical conveyors (20) and the storage-and-retrieval units (22), wherein each of the vertical conveyors (20) is assigned at least one of the transfer locations (T); having a multiplicity of storage-and-retrieval units (22), which can be displaced preferably with rail guidance, preferably substantially only, in the aisles (18), wherein the storage-and-retrieval units (22) store and retrieve the articles preferably in disordered fashion and transport them substantially horizontally along the aisles (18); having a conveying-means level (24): which is substantially barrier-free, in particular free of rack locations (R); which extends horizontally beneath, above or through the rack arrangement (14); which is coupled to the rack arrangement (14) for conveying purposes via the vertical conveyors (20), which extend vertically from the rack arrangement (14) into the conveying-means level (24), wherein each of the vertical conveyors (20) is assigned at least one transfer location (Ü) in the conveying-means level (24); which has a multiplicity of starting points/destinations; and which has a surface area (26) which has a topology made up of a multiplicity of waypoints and segments; and having a material-flow computer (MFR), which has access to the topology and is intended for generating and giving out article-specific, sequence- or distribution-weighted transport orders in order to transport the articles between the rack locations (R) and the starting points/destinations, wherein the transport orders each have a route, in the conveying-means level (24), which represents linked segments and along which the articles are moved in a specific manner between the transfer locations (Ü) and the starting points/destinations, wherein each of the segments connects one of the waypoints to another of the waypoints.