Grid Load Handler Wheel Switching for Modular Container Retrieval
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Solution Overview
Problem
Existing automated storage systems face challenges in providing a lightweight, cost-effective, and modular load handling device that can efficiently maneuver within a grid structure, while maintaining reliability and minimizing maintenance needs.
Innovation Solution
A load handling device with a direction-change assembly featuring a compliant mechanism or linkage-set, allowing wheels to engage and disengage with tracks to change direction, combined with wheels designed for shock absorption and traction, and a drive belt assembly for efficient movement, all made from recyclable materials to reduce costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rectangular tube load handler is used to grip containers at any level, then container accessibility is improved, but the device height must accommodate the largest stack which restricts maximum stack height in enclosed spaces
Solution Approach 1:
The load handling device is divided into multiple modular segments that can be independently positioned. Each segment contains its own gripping mechanism, allowing the system to service containers at any height without requiring a single tall mechanism to reach all levels.
Solution Approach 2:
Instead of solving the height problem in the vertical dimension by making the device taller, the solution moves to the horizontal dimension by distributing multiple shorter load handlers across different grid positions, each serving a specific vertical zone.
2Adaptability or versatility
If complex hoisting mechanisms are used to access specific containers in free-standing stacks, then container retrieval capability is improved, but system cost and complexity increase to impractical levels
Solution Approach 1:
The load handling device is designed as a multi-functional unit that can perform multiple operations: gripping containers, lifting them vertically, transporting them horizontally along grid rails, and depositing them at destination points. This universal design eliminates the need for separate specialized mechanisms for each function.
Solution Approach 2:
The system uses automated robotic load handlers that independently navigate the grid framework and service containers without human intervention, replacing complex manual hoisting mechanisms with self-contained automated units that integrate sensing, navigation, and manipulation capabilities.
3Productivity
If robotic load handlers cover only one grid space each, then load handler density and throughput are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of designing a single complex multi-functional load handler, the system uses multiple simplified identical robotic units, each dedicated to one grid space. These copied units can be manufactured independently and assembled in parallel, reducing individual device complexity while achieving high system throughput through aggregation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient movement and positioning of storage containers within the grid system, reduces maintenance requirements, and lowers operational costs through improved reliability and reduced material usage, while maintaining high performance and adaptability.
Implementation Method 1
a direction-change assembly arranged to raise or lower a first set of wheels and or lower or raise a second set of wheels with respect to the body to engage and disengage the wheels with the parallel tracks, wherein the direction-change assembly comprises a compliant mechanism having at least one resiliently deformable member arranged to move under an applied force
Data Source
AI summary
A grid framework structure includes a first set of parallel rails or tracks and a second set of parallel rails or tracks extending substantially perpendicularly to the first set of rails or tracks in a substantially horizontal plane to form a grid pattern. The grid is supported by a set of uprights to form a plurality of vertical storage locations beneath the grid for containers to be stacked between and be guided by the uprights in a vertical direction. A load handling device includes a body mounted on a first set of wheels and a second set of wheels arranged to engage with the tracks. A gripper assembly is provided for latching to a storage container via a deformable flexure mechanism movable between a locked configuration and a release configuration.