Grid-Based Container Handling System with Extended Transfer Rails
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Solution Overview
Problem
Existing storage and retrieval systems using stacked containers face limitations in efficiently transferring large numbers of containers between different locations, particularly in enclosed spaces like warehouses, due to the need for tall robotic handling devices that restrict stack height and complicate the transfer process.
Innovation Solution
A grid-based object handling system with perpendicular rails allowing robotic load handling devices to move independently along the grid, enabling the transfer of containers between different locations by extending the grid structure beyond the workspace and using vehicles with integrated grid portions for seamless interaction with the handling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a tall robotic handling device is used to extract containers from high stacks, then container accessibility is improved, but the device complexity and space requirements increase
Solution Approach 1:
The system divides the handling function into two independent parts: (1) a standard-height robotic handler that operates within a normal stack height, and (2) a transfer mechanism that moves containers between stacks. This segmentation allows the robotic device to remain compact while still accessing containers in high stacks through coordinated multi-device operation.
Solution Approach 2:
The patent introduces an intermediary transfer mechanism (such as a bridge structure or transfer robot) that acts as a mediator between the robotic handler and containers in high stacks. The intermediary handles the complex task of reaching high containers, allowing the main robotic device to maintain a standard, manageable height.
2Productivity
If the grid structure is extended beyond the workspace, then container transfer efficiency between locations is improved, but the system complexity increases
Solution Approach 1:
The grid structure is designed with universal, standardized components that serve multiple functions: (1) providing structural support for robots, (2) enabling container transfers between stacks, and (3) facilitating connections to external vehicles. The same grid modules used within the workspace can be extended outward to create transfer points, eliminating the need for separate specialized structures.
Solution Approach 2:
The grid structure incorporates dynamic, reconfigurable elements that allow it to adapt its configuration based on transfer needs. Sections of the grid can be extended or repositioned to create temporary transfer points, and the structure can accommodate varying stack heights and container types, reducing the need for fixed, complex infrastructure.
3Speed
If vehicles are positioned for container loading, then transfer speed is improved, but positioning precision requirements increase
Solution Approach 1:
The patent replaces manual or mechanical positioning methods with automated guidance systems. Vehicles are equipped with sensors (such as lasers, cameras, or RFID readers) that automatically detect and align with the grid structure and container positions, eliminating the need for precise manual positioning while maintaining high transfer speeds.
Solution Approach 2:
The system incorporates real-time feedback mechanisms where sensors on vehicles and the grid structure continuously monitor positions and make automatic adjustments. This closed-loop control allows vehicles to self-correct their positioning, achieving the required precision through active control rather than passive mechanical accuracy.
Data Source
AI summary
An object handling system is described, the system having two substantially perpendicular sets of rails forming a grid above a workspace, the workspace having a plurality of stacked containers. The system includes a series of robotic load handling devices operating on the grid above the workspace, the load handling devices having a body mounted on wheels. The robotic devices can move around the grid under instruction from a computing device, the robotic devices being moved to a point on the grid above a stack of containers and then, using a lifting device, engage and lift a container from the stack. The container is then moved to a point where the objects in the container can be accessed. Modifications to the workspace and grid are described that allow vehicles and roll cages to be used to move stacks from the workspace to a point outside the workspace or from outside the workspace into the workspace.