Grid-Based Container Retrieval for High-Density Storage Access
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Solution Overview
Problem
Existing storage systems face inefficiencies in storage density and accessibility, particularly in handling multiple product lines, as they require significant space for aisle access and are not well-suited for selecting single containers from multi-product stacks, especially in enclosed spaces like warehouses.
Innovation Solution
The development of load handling devices that occupy only a single grid space in the storage system, featuring a compact design with a container-receiving space and a lifting device, allowing lateral movement and efficient access to containers stacked in a grid frame structure, which reduces the footprint and enables more devices to operate without obstructing each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional aisle-based storage systems are used to access products, then product accessibility is improved, but storage density deteriorates due to the space required for aisles
Solution Approach 1:
The patent transitions from horizontal aisle-based access to vertical stack-based access. Containers are stacked vertically in columns, and retrieval is achieved by moving load handling devices vertically along the stacks rather than circulating through horizontal aisles. This dimensional change eliminates the need for aisle space while maintaining full access to all containers.
Solution Approach 2:
The patent extracts the access function from the horizontal plane (aisles) and relocates it to the vertical plane (stacks). By removing the requirement for horizontal circulation space, the system achieves high storage density without compromising accessibility, as all containers remain reachable through vertical movement of the load handling devices.
2Ease of operation
If load handling devices with large footprints are used to access containers, then container accessibility is improved, but device density deteriorates due to obstruction between devices
Solution Approach 1:
The load handling device is segmented into distinct functional components: a container-receiving space for holding containers, a lifting device for vertical movement, and a lateral movement mechanism for navigation. This segmentation allows each component to be optimized independently, resulting in a compact overall footprint that enables higher device density without compromising container access capability.
Solution Approach 2:
The device accesses containers through vertical movement along stacks rather than requiring large horizontal clearance. By operating primarily in the vertical dimension and using minimal lateral space for movement between stacks, the device achieves full container accessibility while maintaining a small footprint that allows multiple devices to operate densely in the same space.
3Ease of operation
If tall load handling devices are used to reach containers at any stack level, then container accessibility is improved, but storage system height is increased
Solution Approach 1:
The load handling device employs dynamic components including a movable container-receiving space and an adjustable lifting device that can extend and retract. This dynamic configuration allows the device to reach containers at any vertical level by adjusting its extended height as needed, rather than requiring a permanently tall structure. The device maintains a compact stowed height when not in use while achieving full vertical access during operation.
Solution Approach 2:
The lifting device is positioned and configured in advance to optimize access to containers at different levels. The system pre-positions the container-receiving space and lifting mechanism before retrieval operations begin, allowing efficient access to any stack level without requiring the device to maintain a constantly extended tall configuration, thereby minimizing the effective height requirement.
4Productivity
If single-product stacks are used to simplify retrieval operations, then retrieval speed is improved, but storage efficiency deteriorates due to large floor area requirements
Solution Approach 1:
The load handling device is designed as a universal system capable of retrieving containers from multi-product stacks regardless of product type or stack configuration. The device can access and retrieve any container at any level in any stack, eliminating the need for separate single-product stacks for different product lines. This multi-functional capability allows all products to be stored in shared vertical stacks, maximizing floor space utilization while maintaining efficient retrieval operations through vertical access.
Data Source
AI summary
A storage system and a load handling device for lifting and moving containers stacked in the storage system are described. The storage system includes a plurality of rails or tracks arranged in a grid pattern above the stacks of containers. The grid pattern can include a plurality of grid spaces and each stack is located within a footprint of only a single grid space. The load handling device is configured to move laterally on the rails or tracks above the stacks. The load-handling device includes a container-receiving space located above the rails or tracks in use and a lifting device arranged to lift a container from a stack into the container-receiving space. The load handling device has a footprint that, in use, occupies only a single grid space in the storage system.