Coupled Tote Row Layout for High-Density Fast Retrieval
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated storage and retrieval systems face limitations in storage density and retrieval efficiency due to the constraints of carrier movement and vertical stacking of totes, which hinder access to items buried deep in stacks.
Innovation Solution
A horizontal arrangement of totes within rows, mechanically coupled to allow simultaneous movement and retrieval of multiple totes by pulling or pushing one tote, combined with a system of drives for constant velocity, acceleration, and side shifting to facilitate efficient storage and retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If totes are stacked vertically to maximize storage density, then storage density is improved, but retrieval speed deteriorates due to the time required to lift totes from the top one-by-one
Solution Approach 1:
The patent transitions from vertical stacking to horizontal arrangement of totes in rows. Instead of stacking totes vertically where retrieval requires lifting from the top, totes are arranged horizontally in rows that can be moved collectively. This dimensional change allows any tote in a row to be accessed by moving the entire row to the front, eliminating the sequential retrieval limitation of vertical stacking while maintaining high storage density through multi-layer horizontal rows.
Solution Approach 2:
The patent mechanically couples multiple totes in a row together using coupling mechanisms that connect adjacent totes. This merging allows the entire row of totes to be moved as a single unit by applying force to one tote, enabling simultaneous movement of multiple totes and dramatically improving retrieval speed compared to handling totes individually.
2Ease of operation
If carriers move between aisles of products to enable retrieval, then accessibility is improved, but storage density deteriorates due to the space required for carrier movement
Solution Approach 1:
The patent segments the storage structure into multiple independent rows of totes, where each row can be moved independently by a carrier. This segmentation allows the carrier to service multiple rows without requiring large aisles for maneuvering, as the carrier can access individual rows directly. The segmented row structure maintains high storage density while preserving accessibility to all totes.
Solution Approach 2:
The patent changes from vertical stacking to horizontal row arrangements, allowing carriers to access totes from the side rather than requiring vertical lifting operations. This dimensional reorganization enables more efficient use of space, as horizontal rows can be packed more densely while still allowing carrier access without large movement corridors.
3Loss of time
If totes are arranged in horizontal rows and mechanically coupled, then retrieval speed is improved by pulling multiple totes simultaneously, but device complexity increases due to coupling mechanisms
Solution Approach 1:
The coupling mechanisms are designed to automatically engage and disengage based on the relative positions and movements of adjacent totes. When totes are pushed together during row formation, the coupling mechanisms self-engage without requiring additional actuators or complex control systems. Similarly, when a row is moved to the front for retrieval, the leading tote can be easily decoupled from the rest of the row, providing self-service functionality that reduces overall system complexity.
Solution Approach 2:
The patent replaces complex active coupling mechanisms with simpler passive coupling designs that rely on mechanical interference or friction-based connections. The coupling structures use straightforward geometric features that engage through direct contact and simple forces, eliminating the need for motors, sensors, or complex control algorithms, thereby reducing device complexity while maintaining the ability to move rows as unified units.
Data Source
AI summary
Disclosed herein is a high-density storage system comprising a plurality of layers, each layer comprising a plurality of rows for storing a plurality of coupled totes and one or more carriers located on opposite ends of each layer, each carrier being multiple rows wide, each carrier capable of retrieving totes from a row in the layer, depositing a tote into a row or oral in a layer and shifting totes from one row to another within the layer.