Dual-Shuttle Rack Storage With Conveyor Pallet Transfer
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Solution Overview
Problem
Existing cart-based rack systems in warehousing face inefficiencies as systems grow larger, requiring improvements in cart functionality and rack design to enhance storage and retrieval efficiency.
Innovation Solution
A dual shuttle system comprising a first cart movable along an aisle and a second cart carriable by the first cart, with a conveyor for loading and unloading items, and a raisable top platform for lifting items, powered by an electrified rail or energy storage devices, allowing for faster and more efficient movement within the rack system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cart-based rack systems are used for automated storage and retrieval, then floor space usage is reduced and loading/unloading speed is improved, but system capacity is limited and cart functionality becomes insufficient as racks grow larger
Solution Approach 1:
The system is divided into multiple independent carts that can operate simultaneously within the rack structure. Each cart is equipped with its own drive mechanism and can independently travel along the rack beams, allowing parallel operations to increase overall system capacity while maintaining fast loading and retrieval speeds.
Solution Approach 2:
The invention introduces vertical movement capability to the carts through raise/lower mechanisms that allow carts to move between different levels of the rack structure. This three-dimensional movement enables carts to access storage locations at various heights, effectively increasing system capacity without proportionally increasing floor space requirements.
2Quantity of substance
If rack systems become larger to increase storage capacity, then more goods can be stored in given square footage, but cart functionality and rack design must be improved to handle the increased size
Solution Approach 1:
The rack structure incorporates universal features such as standardized drive mechanisms, interchangeable cart components, and modular beam configurations that allow the same basic design to handle varying storage capacities. This multi-functionality enables the rack system to accommodate different quantities of goods without requiring proportional increases in overall system complexity.
Solution Approach 2:
Multiple identical or standardized cart units are deployed within the rack system, each capable of performing the same functions. This replication allows the system to handle larger storage capacities by simply adding more standard units rather than designing custom complex mechanisms for each additional storage location.
3Productivity
If multiple carts are used to increase system capacity, then more items can be stored and retrieved simultaneously, but the complexity of managing and coordinating multiple carts increases
Solution Approach 1:
The system incorporates sensors and control mechanisms that provide real-time feedback on cart positions, occupancy status, and operational state. This feedback enables centralized control to coordinate multiple carts efficiently, assigning tasks and optimizing routes to maximize the number of pallet moves per hour while preventing conflicts and coordination errors.
Data Source
AI summary
A storage system includes a rack with a plurality of layers, each layer including an aisle and a plurality of rows extending from the aisle defining storage locations for items. A shuttle usable with the rack includes a first cart movable along the aisle and a second cart configured to be carriable by the first cart and to be movable along a row. The second cart is configured to carry an item between the first cart and the storage locations. A conveyor is located on one of the first or second carts to move the item onto or off the first cart. Related methods of storing and/or retrieving items from a rack are also disclosed. A rack system is disclosed and is readily assembled without welding, transferring loading so that the weight of the rack and any item stored therein is supported by the upright elements via support brackets.