Overhead Portal Robot Supply for Simultaneous Dynamic Rack Operations
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Solution Overview
Problem
Conventional dynamic shelving systems cannot operate simultaneously in retrieval and storage modes, requiring separate locations for picking and replenishment, which limits efficiency and space utilization.
Innovation Solution
A system and method that supplies dynamic shelves from above using a gantry robot and conveyor system, allowing simultaneous operation in both modes without interference, optimizing space usage and eliminating the need for additional floor space for replenishment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If dynamic shelving uses the same location for both retrieval and storage operations, then the system structure is simplified, but simultaneous operation in both modes becomes impossible
Solution Approach 1:
The patent divides the dynamic shelving system into two distinct operational zones: a lower picking area for retrieval operations and an upper storage area for replenishment operations. This spatial segmentation allows both modes to operate simultaneously without interference, resolving the contradiction between structural simplicity and simultaneous operation capability.
2Productivity
If separate locations are provided for picking and replenishment operations, then simultaneous operation is enabled, but additional floor space is required
Solution Approach 1:
The patent transitions from a horizontal layout to a vertical layout by utilizing the height dimension. The picking area is positioned at the lower level while the storage area is positioned at the upper level, allowing both operations to occur simultaneously without requiring additional floor space. This vertical arrangement resolves the contradiction between simultaneous operation capability and floor space utilization.
3Reliability
If dynamic shelving operates in single mode only, then operational conflicts are avoided, but throughput efficiency is reduced
Solution Approach 1:
By segmenting the system into dedicated picking and storage zones at different vertical levels, the patent eliminates operational conflicts while enabling simultaneous dual-mode operation. This segmentation maintains operational stability in each zone while maximizing overall throughput efficiency through parallel processing.
4Device complexity
If replenishment is performed from the same level as picking, then equipment simplicity is maintained, but collisions between operations occur
Solution Approach 1:
The patent eliminates collisions by moving the replenishment operation to a different vertical dimension (upper level) while keeping the picking operation at the lower level. This vertical separation removes the harmful interaction between operations while maintaining equipment simplicity, resolving the contradiction between equipment arrangement and collision avoidance.
Data Source
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AI summary
A method and a system for supplying a dynamic rack with articles are disclosed, the system comprising: the dynamic rack, which is a paternoster rack or a storage lift and which is configured for storing and picking the articles, wherein the dynamic rack comprises a stationary rack frame and a plurality of vertically movable storage devices such that the storage devices are arranged vertically one above the other in a variable arrangement, each of the storage devices being adapted to directly receive one or more of the articles or to indirectly receive them in one or more load carriers; a gantry robot for transporting the storage devices, articles and/or load carriers from the dynamic rack and into the dynamic rack, wherein the gantry robot comprises a gantry frame and a gripping unit, the gripping unit being coupled to the gantry frame and being movable along at least two axes;and a conveyor system for supplying the gripping unit of the portal robot with the storage equipment, articles and/or load carriers; wherein the portal frame vertically extends above the dynamic rack, so that the storage equipment, articles and/or load carriers can be exchanged from above by means of the gripping unit between the dynamic rack and the conveyor system;