Gapless Tray Stacking for Compact Storage Volume Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing storage and picking systems for goods, particularly 'slow movers,' are inefficient due to excessive space usage and high construction costs, as they require multiple layers and rail-supported compartments, leading to suboptimal use of storage volume and width.
Innovation Solution
A method where goods are directly layered on trays without vertical gaps, allowing for compact storage and reduced width, with the option of using pallets as trays or additional storage aids, and employing a stacker crane for efficient storage and retrieval, eliminating the need for rail-supported compartments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If goods are stored on trays with multiple layers and rail-supported compartments, then storage capacity is increased, but the gross volume required and construction costs increase
Solution Approach 1:
The patent removes the rails from the storage compartment design, extracting the unnecessary structural element that was providing lateral support. By eliminating the rails, the storage compartment can achieve the required stability and load-bearing capacity through the tray structure itself and the stacking mechanism, thereby reducing the gross volume required while maintaining storage capacity.
Solution Approach 2:
The patent transitions from a design that relies on lateral rail support to a design that utilizes vertical stacking dimension. By stacking trays vertically with gapless layering, the system achieves storage capacity through the vertical dimension rather than requiring extensive lateral rail structures, thus reducing the overall gross volume required.
2Strength
If rail-supported compartments are used for tray storage, then structural support is provided, but construction costs and device complexity increase
Solution Approach 1:
The patent extracts and removes the rails from the storage compartment structure. The structural support function previously provided by the rails is redistributed to the tray design itself and the stacking mechanism, eliminating the need for separate rail components and reducing construction complexity.
Solution Approach 2:
The patent merges the structural support function into the tray structure and stacking mechanism rather than having separate rail components. The tray design itself incorporates the necessary structural elements, and the stacking mechanism provides the additional support, combining multiple functions into a simpler integrated system.
3Ease of operation
If vertical gaps are left between stacked units, then easy access and safety are ensured, but the gross volume required increases
Solution Approach 1:
The patent implements a preliminary stacking arrangement where trays are stacked gaplessly from the beginning. The handling structures and stacking mechanism are designed in advance to enable safe manipulation and access to stacked units without requiring vertical gaps, thereby achieving compact volume utilization while maintaining operational safety.
Solution Approach 2:
The patent introduces handling structures as intermediaries between the stacked trays and the operating personnel or automated systems. These handling structures enable safe access and manipulation of stacked units without requiring vertical gaps, allowing compact stacking while maintaining ease of operation through the intermediary handling mechanisms.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention proposes a method for storing and order-picking articles using pallets (10), on which articles (5) of the same type are arranged in a plurality of horizontal layers, wherein each layer contains a plurality of the articles (5). The pallet (10) is emptied, and the articles removed in this way are transferred onto trays (20) provided with handling structures (22A, 22B) for a storage- and retrieval unit, wherein each tray is loaded with just one layer of articles. The trays loaded in this way are transported to a storage location (31) within a storage region (30), a stack of articles being built up in the process from the loaded trays (20).