Grid Load Handler Battery Exchange for Charging Downtime

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Load handling devices in automated storage and retrieval systems face significant downtime due to the long charging time of rechargeable power sources, such as batteries, which affects the efficiency of order fulfillment in logistics systems.

Innovation Solution

A method for exchanging power sources in load handling devices on a grid framework structure, where a depleted power source is removed from the device, inserted into a storage container, and replaced with a fully charged power source from another storage container, all performed on the grid framework structure without the need for the device to travel to a separate exchange station.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the load handling device uses a rechargeable power source that is charged at a charge station, then the power source can be recharged, but the charging time is significant (up to a couple of hours) which reduces operational time and increases downtime

Engineering Contradiction:

Improvepower source availabilityVSAvoidcharging time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system pre-charges multiple power sources at charge stations before they are needed. When a load handling device requires power, a fully charged power source is already available for immediate exchange, eliminating the need to wait for charging during operational cycles

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The load handling device autonomously exchanges its own power source at exchange stations without requiring external assistance. The device can independently remove a depleted power source and install a charged one, maintaining continuous operation

Inventive Principle:

Principle #25Self-service

2Reliability

If the load handling device travels to a second exchange station to receive a new rechargeable power source after power removal, then a replacement power source can be obtained, but the device loses power supply and communication during travel

Engineering Contradiction:

Improvepower source replacementVSAvoidcontinuous operation capability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

An auxiliary power source acts as an intermediary to provide temporary power during the exchange process. This auxiliary power source enables the load handling device to travel between exchange stations and maintain communication with the control system while the primary power source is being replaced

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system pre-positions charged power sources at exchange stations before they are needed. This allows for rapid exchange without requiring the device to travel long distances or wait for power source preparation

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250091473A1Power sources of load handling devices operative on a grid framework structure

Publication Date: 2025.03.20 OCADO INNOVATION LTD

AI summary

A method for exchanging a power source in a load handling device operative on a grid framework structure, the grid framework structure including a track system extending in a substantially horizontal plane and forming a grid pattern containing a plurality of grid cells; a plurality of upright columns supporting the track system; and a plurality of stacks of storage containers arranged in a plurality of storage columns located below the track system. The method includes removing a first power source from the load handling device; inserting the first power source into a first storage container in a first grid cell; removing a second power source from a second storage container in a second grid cell; and inserting the second power source into the load handling device.