Distributed ASRS Control for Storage Density and Throughput
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Solution Overview
Problem
Automated storage and retrieval systems (ASRS) in warehouses and stores face inefficiencies due to the trade-off between storage space efficiency and transport efficiency, where optimizing one factor often detracts from the other, leading to minimal overall efficiency gains.
Innovation Solution
The implementation of a control system with separate and distinct controllers managing storage and transport operations independently, using autonomous vehicles and dynamic storage location allocation to optimize storage and retrieval processes, allowing for decoupled planning and control of storage and retrieval systems to enhance throughput performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If storage locations are densely packed or multiple levels are added to increase storage space efficiency, then storage space efficiency is improved, but transport time and complexity increase
Solution Approach 1:
The control system is divided into multiple independent controllers, each managing a specific zone or aspect of the ASRS. This segmentation allows parallel processing of storage and retrieval operations across different zones, reducing overall transport time while maintaining high storage density.
Solution Approach 2:
The system transitions from centralized to distributed control architecture, adding a spatial dimension to control management. Multiple controllers operate independently across different levels and zones, enabling simultaneous operations that reduce transport time while maintaining vertical storage efficiency.
2Productivity
If autonomous vehicles are given greater freedom of movement and higher transport speeds to improve transport efficiency, then transport efficiency is improved, but system complexity and coordination difficulty increase
Solution Approach 1:
The control system is divided into multiple independent controllers, each managing a specific zone or aspect of the ASRS. This segmentation allows parallel processing of storage and retrieval operations across different zones, reducing overall transport time while maintaining high storage density.
Solution Approach 2:
Each controller operates autonomously to manage its designated zone, making local decisions without constant centralized coordination. This self-service approach reduces communication overhead and system complexity while maintaining high transport speeds and efficiency.
3Productivity
If dynamic allocation of storage locations is implemented to improve storage throughput, then storage throughput is improved, but control complexity and coordination requirements increase
Solution Approach 1:
The control system is divided into multiple independent controllers, each managing a specific zone or aspect of the ASRS. This segmentation allows parallel processing of storage and retrieval operations across different zones, reducing overall transport time while maintaining high storage density.
Solution Approach 2:
The system implements dynamic storage location allocation where controllers can adaptively assign and reassign storage locations based on real-time conditions. This dynamic approach improves storage throughput while the distributed architecture keeps control complexity manageable through localized decision-making.
Data Source
AI summary
An automated storage and retrieval system includes a storage space with storage locations defined therein, an automated transport system connected to the storage space and configured to transport store units for storage in the storage locations and retrieval from the storage locations, and a control system disposed for managing throughput performance of the automated storage and retrieval system, the control system being operably coupled to the automated transport system and having more than one separate and distinct control sections each configured for managing throughput performance with respect to a common group of the storage locations, wherein at least one of the control sections manages aspects of throughput performance of the common group independent of another of the control sections.