Dual-Carriage Access Station for Faster Container Presentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated storage and retrieval systems face inefficiencies in accessing storage containers due to complex and spacious access stations with numerous moving components, leading to reduced throughput and increased maintenance needs.
Innovation Solution
A compact access station design featuring a guiding frame with a primary and secondary carriage system, where the primary carriage minimizes travel distance by using a transfer device to move storage containers between the carriages, allowing for simultaneous preparation and presentation of subsequent containers, thereby increasing storage container frequency and reducing the complexity of the access station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional access station design is used, then the storage container can be accessed, but the access station becomes complex and spacious with numerous moving components, reducing throughput and increasing maintenance needs
Solution Approach 1:
The access station is divided into two independent carriages (first carriage and second carriage) that operate separately on the same guiding frame. Each carriage has its own storage container support and can independently receive, present, and return storage containers. This segmentation eliminates the need for complex moving components in a single unified system, as each carriage is a simpler, modular unit.
Solution Approach 2:
While the first carriage is presenting a storage container to the picker, the second carriage simultaneously receives a subsequent storage container in preparation. This preliminary action ensures that when the first carriage returns to the receiving area, a storage container is already ready on the second carriage for immediate presentation, eliminating idle time and increasing throughput without adding complexity.
2Productivity
If the primary carriage travels to the receiving area after presenting a container, then the container can be retrieved, but the travel time reduces the frequency of container presentation
Solution Approach 1:
The second carriage receives and prepares the subsequent storage container while the first carriage is still at the picking position presenting the current container. This preliminary preparation eliminates the idle travel time that would otherwise occur when the first carriage returns empty to receive the next container, as the second carriage is already positioned with a ready container.
Solution Approach 2:
The dual carriage system ensures continuous useful action by overlapping the presentation cycle of one carriage with the receiving cycle of the other. While the first carriage is engaged in presentation (useful action), the second carriage performs receiving (useful action), ensuring that at least one carriage is always productive and eliminating periods of idle travel.
3Adaptability or versatility
If more moving components are added to the access station, then more functions can be performed, but maintenance requirements and complexity increase
Solution Approach 1:
By segmenting the access station into two independent carriages, each with minimal moving components, the system achieves versatility through coordination rather than through complex individual units. Each carriage is a simple, modular unit that can be easily maintained or replaced, while the overall system provides enhanced functionality through the interaction of the two carriages.
Solution Approach 2:
The carriages are designed to operate independently with minimal intervention. Each carriage can autonomously receive, present, and return storage containers without requiring complex control mechanisms or additional moving parts. This self-service design reduces maintenance requirements while maintaining full functionality.
Data Source
AI summary
An access station, which is for presentation of a storage container from an automated storage and retrieval system to a picker, has a receiving area for receiving storage containers, forward of the receiving area a picking position for picking products from the storage container. The access station includes a guiding frame, a primary carriage, and a secondary carriage. The guiding frame is arranged in a horizontal plane and extends between the picking position and the receiving area. The primary carriage, which is for transporting a storage container, includes a primary carriage base, a primary carriage displacement motor, a first storage container support, and a transfer device. The primary carriage base is movable along the guiding frame. The primary carriage displacement motor is configured to move the primary carriage along the guiding frame. The first storage container support is connected to the primary carriage base. The transfer device is for displacement of a storage container positioned on the first storage container support. The secondary carriage, which is for transporting a storage container, includes a secondary carriage base, a secondary carriage displacement motor, and a second storage container support. The secondary carriage base is movable along the guiding frame. The secondary carriage displacement motor is configured to move the secondary carriage along the guiding frame. The second storage container support is connected to the secondary carriage base. The secondary carriage is configured to receive a storage container being displaced from the primary carriage by the transfer device.