Dual Shuttle Storage System for High Throughput Warehousing
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Solution Overview
Problem
Existing cart-based rack systems for warehousing face inefficiencies as they become larger, particularly in terms of cart functionality and rack design, which hinders the ability to handle increased storage capacity and maintain high throughput.
Innovation Solution
The implementation of a dual shuttle system with aisle and row carts, equipped with motors and conveyors, that electronically determine item size and characteristics to optimize storage and retrieval processes, adhering to load movement protocols to ensure efficient movement within the rack system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rack systems become larger to increase storage capacity, then storage capacity is improved, but cart functionality and efficiency deteriorate
Solution Approach 1:
The system divides the rack structure into multiple tiers with aisles and rows, and segments the cart system into aisle carts and row carts that operate independently in different zones. This segmentation allows each cart type to be optimized for its specific function while the overall system handles large storage capacity, resolving the contradiction between system size and cart efficiency.
2Quantity of substance
If rack systems become larger to increase storage capacity, then storage capacity is improved, but time required for pallet moves increases
Solution Approach 1:
The system determines storage positions electronically before physical movement occurs, and aisle carts deliver items to row carts in advance of final placement needs. This preliminary action reduces the time required for actual pallet moves while maintaining the ability to handle large storage capacities across multiple tiers.
Solution Approach 2:
Multiple aisle carts and row carts operate simultaneously and continuously throughout the rack system, with aisle carts transporting items to row carts that are ready to receive and place them. This continuous parallel operation maintains high throughput efficiency even as the rack system scales to larger storage capacities.
3Device complexity
If single cart systems are used for simplicity, then device complexity is reduced, but functionality and adaptability deteriorate
Solution Approach 1:
Both aisle carts and row carts are designed with universal capabilities to transport various item types and sizes, while also having specialized functions - aisle carts navigate vertical aisles between tiers, and row carts operate horizontally within rows. This multi-functionality provides adaptability without requiring overly complex individual cart designs.
Solution Approach 2:
Row carts serve as intermediaries between aisle carts and final storage positions. Aisle carts deliver items to row carts, which then complete the placement in specific row locations. This intermediary role allows the system to maintain simple, robust cart designs while achieving complex storage and retrieval functionality through coordinated operation.
Data Source
AI summary
Methods of storage and/or retrieval of items from storage racks using carts include electronically determining a size of an item and determining a storage position in a row for the item based on the determined size. The size can be determined by reading indicia on the item and consulting a database to determine a size of the item based on the read indicia. Other methods include electronically determining a characteristic of an item and determining a load movement limit protocol for the item based on the determined characteristic. The protocol may limit velocity or acceleration of movement of the item.