Object handling system and method
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Solution Overview
Problem
Existing storage and retrieval systems using freestanding stacks of containers are impractical for commercial use due to high costs and restricted height limitations, which hinder efficient transfer of containers between different locations, especially in enclosed spaces like warehouses.
Innovation Solution
A grid-based object handling system with perpendicular rails supporting robotic load handling devices, allowing independent movement and container exchange between stacks, with extendable grid portions for interfacing with vehicles and external locations, enabling efficient transfer of containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If freestanding stacks of containers are used with hoisting mechanisms, then container storage density is improved, but system cost and complexity increase significantly
Solution Approach 1:
The patent replaces complex hoisting mechanisms with a simplified robotic arm system that operates on a grid structure. The robotic arms move along predefined grid paths and use simpler lifting mechanisms, substituting the complicated hoisting systems with a more manageable robotic manipulation approach that reduces overall system complexity while maintaining storage density.
Solution Approach 2:
The grid structure serves as an intermediary element between the containers and the robotic manipulation system. This grid provides a standardized interface that simplifies the interaction between robotic arms and containers, enabling easier container handling without requiring complex direct manipulation mechanisms, thereby reducing system complexity.
2Ease of operation
If tube height is increased to extract highest stacks, then container accessibility is improved, but space utilization in enclosed areas deteriorates
Solution Approach 1:
The patent segments the container handling system into multiple robotic arms operating at different grid levels, rather than using a single tall tube mechanism. This segmentation allows containers to be accessed from multiple heights simultaneously, improving accessibility without requiring a single structure to reach the maximum stack height, thus better utilizing enclosed space.
Solution Approach 2:
Instead of solving the accessibility problem by increasing vertical height (one dimension), the patent introduces horizontal movement along grid lines and multi-level robotic positioning (additional dimensions). This dimensional approach allows containers at any height to be accessed by moving robotic arms to appropriate grid positions, improving accessibility without increasing overall system height and maintaining better space utilization.
3Productivity
If multiple robotic load handlers cover one grid space, then system throughput is improved, but device density and complexity increase
Solution Approach 1:
The patent implements dynamic task allocation and coordination among robotic arms based on real-time system state and container demand. Rather than having fixed, redundant robotic handlers, the system dynamically assigns tasks to available robotic arms, optimizing throughput without requiring excessive device density. This dynamic coordination reduces the number of physical devices needed while maintaining high productivity.
Solution Approach 2:
Each robotic arm is designed with universal capabilities to handle multiple container types and perform various operations (picking, placing, transferring) across different grid locations. This multi-functionality allows a smaller number of versatile robotic arms to achieve the same throughput as multiple specialized handlers, reducing device density and system complexity while maintaining productivity.
Data Source
AI summary
A system, comprising:a storage workspace including a first framework defined by a series of first uprights, the first uprights supporting a grid of two substantially perpendicular sets of rails; anda plurality of containers for storing objects, wherein the plurality of containers are arranged in stacks, each stack of containers is located underneath a grid space in the workspace; anda grid extension including a continuation of the two substantially perpendicular sets of rails, and wherein the plurality of containers can be moved by one or more load handling devices between the storage workspace and an area beneath the grid extension, wherein the area beneath the grid extension is configured for positioning a roll cage such that containers can be placed or removed from the roll cage.