Grid Load Handler Redundancy for Fault Recovery in ASRS
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Solution Overview
Problem
Existing automated storage systems face inefficiencies due to the need for complex hoisting mechanisms and limited height restrictions, leading to impractical costs and operational disruptions when faults occur in load handling devices.
Innovation Solution
A fault-tolerant load handling device with redundant wheel and motor configurations, allowing independent power sources and synchronized wheel engagement, enabling flexible movement and self-recovery capabilities, and a gripper assembly for secure container handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex hoisting mechanisms are used to access containers in stacks, then container accessibility is improved, but system cost and complexity increase significantly
Solution Approach 1:
The patent replaces traditional mechanical hoisting mechanisms with an automated robotic system that uses sensors, controllers, and automated gripping mechanisms to handle containers. This substitution reduces mechanical complexity while improving accessibility and operational efficiency through automation.
Solution Approach 2:
The robotic system performs self-positioning and self-operating functions to access containers in stacks autonomously. The system uses sensors to detect container positions and automatically navigates to retrieve containers without requiring complex external hoisting mechanisms.
2Reliability
If load handling devices operate without redundancy, then device simplicity is maintained, but operational reliability decreases when faults occur
Solution Approach 1:
The patent incorporates redundant motors and wheels in the load handling device before faults occur. This redundancy acts as a preventive measure, ensuring that if one component fails, the system can continue operating using the backup components, thereby maintaining operational reliability.
Solution Approach 2:
The system dynamically changes operational parameters by switching from using one motor to another when a fault is detected. The control system adjusts the configuration of active components based on real-time operational status, maintaining system functionality despite component failures.
3Productivity
If the tube height is increased to extract the highest stack in a single operation, then extraction efficiency is improved, but the system requires more enclosed space
Solution Approach 1:
The patent divides the container extraction process into multiple operations rather than requiring a single high tube operation. The robotic system can access containers at different heights in sequence, eliminating the need for an excessively high tube structure while maintaining extraction capability.
Solution Approach 2:
Instead of increasing vertical tube height, the system uses horizontal movement and multi-level access strategies. The robotic load handler moves horizontally along tracks and can service multiple stack heights, transforming the problem from a vertical dimension solution to a horizontal multi-level approach.
4Productivity
If robotic load handlers cover only one grid space each, then load handler density and system throughput are improved, but device complexity increases
Solution Approach 1:
The patent designs load handling devices with universal functionality that can operate within a single grid space while performing multiple tasks. The redundant motor and wheel configurations enable each device to handle various operational scenarios independently, achieving high throughput without requiring complex multi-device coordination.
Data Source
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AI summary
A load handling device is provided for lifting and moving storage containers (10) stacked in a grid framework (14) structure comprising: a first set of parallel rails or tracks (22a) and a second set of parallel rails or tracks (22a) extending substantially perpendicularly to the first set of rails or tracks (22b) in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, wherein the grid is supported by a set of uprights (16) to form a plurality of vertical storage locations beneath the grid for containers (10) to be stacked between and be guided by the uprights in a vertical direction through the plurality of grid spaces, the load handling device comprising: a body mounted on a first set of wheels (116) being arranged to engage with the first set of parallel tracks (22a) and a second set of wheels being arranged to engage with the second set of parallel tracks (22b); and a lifting assembly comprising a sling assembly arranged to support, raise and lower a load, the sling assembly comprising: a sling extending between a support mountable to the body of the load handling device and a gripper plate for supporting the load, wherein the first end of the sling is attached to a hoist drum and the second end of the sling is attached to a hoist drum.