Circular Vehicle Routing in High-Bay Warehouse Shuttles
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Solution Overview
Problem
Existing storage and retrieval systems in rack storage systems are limited by single operating device usage per shelf level, leading to reduced throughput and inability to handle high picking rates, especially when multiple storage and retrieval operations are required simultaneously.
Innovation Solution
A method that allows multiple vehicles to operate simultaneously on the same level, with defined one-way travel directions and vertical lifts, enabling efficient storage and retrieval operations across multiple shelf levels without collisions, and includes a scalable design for flexible expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single operating device is used per shelf level to prevent collisions, then device complexity is reduced, but productivity decreases because multiple storage and retrieval operations cannot be performed simultaneously
Solution Approach 1:
The patent introduces a vertical dimension to the problem by implementing multiple rack levels with shuttles operating at different heights. Instead of allowing multiple shuttles on the same level (which would cause collisions), the system stacks shuttles vertically across multiple levels, each served by dedicated lifts. This dimensional transformation enables parallel operations without horizontal collision risks.
Solution Approach 2:
The patent segments the rack aisle into multiple independent levels, with each level having its own shuttle and lift combination. This segmentation allows independent operation of each level, enabling simultaneous storage and retrieval operations across different levels without interference, thereby increasing overall throughput while maintaining simple collision-free operation at each level.
2Quantity of substance
If shuttles are moved vertically using a stationary lift at the front of the aisle, then fewer shuttles are required, but the lift becomes a performance-limiting factor for high picking rates
Solution Approach 1:
The patent distributes the vertical transport function across multiple lift stations positioned at different locations along the rack aisle, rather than concentrating all vertical movement through a single front lift. This spatial distribution of lift resources eliminates the bottleneck effect, allowing multiple shuttles to be vertically transported simultaneously at different positions, thereby supporting high picking rates while maintaining efficient shuttle utilization.
3Adaptability or versatility
If operator panels are moved repeatedly forwards and backwards within the aisle to access storage locations, then adaptability to any storage position is achieved, but loss of time increases due to constant direction changes
Solution Approach 1:
Instead of moving the operator panel (shuttle) back and forth to access different storage locations, the patent inverts the approach by bringing the storage locations to the operator panel. The shuttle transports storage containers to a fixed picking station where orders are assembled, eliminating the need for the operator panel to repeatedly change direction and access scattered storage positions throughout the aisle.
Solution Approach 2:
The patent extracts the picking function from the moving shuttle and places it at a stationary picking station. The shuttle's role is reduced to transporting storage containers to and from the picking station, while the complex operation of order assembly and item selection is performed at the fixed station. This separation eliminates time loss from directional changes and enables continuous shuttle operation.
Data Source
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AI summary
A method for operating a high-bay warehouse (10) is disclosed, said warehouse having a multiplicity of shelves (12-1, 12-2), which define at least one aisle of shelves (14-1) between them in the longitudinal direction (X), wherein each shelf (12) has a multiplicity of shelf levels (E) arranged one above the other, wherein a first vehicle lift (16; 18-1) is arranged at the beginning of the at least one aisle of shelves (14-1) and a second vehicle lift (16; 20-1) is arranged at the end of the at least one aisle of shelves (14-1), which lifts use their load picking-up means for respectively raising or lowering at least one vehicle (22), which is designed for storing and retrieving storage units (26) in and from storage locations (28) on the shelf levels (Ei), to a desired height of one of the shelf levels (Ei), wherein the at least one aisle of shelves (14-1) is defined by a multiplicity of vehicle channels (30) arranged one above the other, wherein each vehicle channel (30) extends along at least one of the shelf levels (Ei) through the at least one aisle of shelves (14-1), comprising the following steps: establishing for each channel (30) a fixed travelling direction (32) for the vehicles (22), such that the vehicles (22) travel through a respective channel (30) of the at least one aisle of shelves (14-1) exclusively either from the first lift (18-1) to the second lift (20-1) or vice versa; establishing a fixed transporting direction (34) for each lift (16; 18-1, 20-1), such that the first or the second vehicle lift (18-1, 20-1) transports the vehicles (22) exclusively upwards and the other vehicle lift (20-1, 18-1) transports the vehicles (22) exclusively downwards; and, if there is a connecting path (38) for the vehicles (22) outside the at least one aisle of shelves (14-1) between the first lift (18-1) and the second lift (20-1), establishing a fixed travelling direction (36) for the connecting path (38), such that the vehicles (22) travel exclusively between the first lift (18-1) and the second lift (20-1), or vice versa; wherein the transporting and travelling directions (32, 34, 36) are established such that the vehicles (22) travel through the at least one aisle of shelves (14-1) along closed travelling path loops.