Gantry Tote Handler for Dense Storage and Retrieval
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Solution Overview
Problem
Existing warehouse systems face inefficiencies in storing and retrieving a large number of different product items due to the impracticality of single-product stacks, which require extensive floor space and are not suitable for perishables or infrequently ordered goods.
Innovation Solution
A mechanical handling apparatus and method for automatically receiving and moving shipping containers or totes within a storage and retrieval system, utilizing a gantry frame and tote handler equipped with optical sensors, actuators, and pushing arms to efficiently transfer totes between spurs and loading frames, enabling dense storage and efficient access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single-product stacks are used to store different product items, then product variety can be accommodated, but floor space requirement increases significantly
Solution Approach 1:
The patent transitions from horizontal floor space utilization to vertical space utilization by implementing multi-level stacking systems. Products are stored in vertically stacked containers and bins arranged in three-dimensional grids, allowing the system to store tens or hundreds of thousands of different product lines without proportionally increasing floor area. This dimensional transformation resolves the contradiction between storing product variety and minimizing floor space.
2Ease of manufacture
If single-product stacks are used for all items, then simple storage is achieved, but efficiency decreases for perishables and infrequently-ordered goods
Solution Approach 1:
The patent implements multi-product stacks where single containers can hold multiple different product types simultaneously. The system is designed to accommodate diverse products including perishables and infrequently-ordered goods within the same storage structure, using standardized containers that can be universally handled by robotic systems. This multi-functionality allows efficient handling of various product types without requiring separate simple storage systems for each, thus resolving the contradiction between storage simplicity and handling efficiency.
3Device complexity
If manual handling methods are used for totes, then system complexity is reduced, but labor requirements and processing time increase
Solution Approach 1:
The patent implements automated robotic handling systems that perform tote retrieval, transport, and placement operations autonomously. The robotic pickers and conveyors operate without human intervention, automatically navigating the storage framework, identifying target products, and executing handling operations. This self-service automation eliminates manual labor while managing system complexity through integrated control systems, thereby resolving the contradiction between reduced device complexity and reduced processing time.
Data Source
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Figure 3a~3c
AI summary
An apparatus for manipulating containers or totes, the apparatus being configured to: receive a container from a spur of a semi-automated or automated storage and retrieval system and a first position; move the container to a second position, which corresponds to a predetermined location relative to a loading frame; and to move the container into a first destination location within the loading frame. Optionally, the container may then be moved to a second destination within the loading frame.