Grid Load Handler Wheel-Lift Layout for Dense Bin Retrieval
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Solution Overview
Problem
Existing load handling systems for dense storage of diverse products face inefficiencies due to high space requirements and limited access to containers within multi-product stacks, particularly in enclosed spaces, where the need for large aisles or complex hoisting mechanisms restricts storage density and accessibility.
Innovation Solution
A load handling device with a reduced footprint, featuring wheels and a crane mechanism that allows two-dimensional movement above the stacks, enabling efficient lateral movement and vertical lifting of containers, thereby optimizing space usage and access to containers at any stack level without obstructing other devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rectangular tube load handler is used to grip containers at any level in the stack, then containers can be lifted at once from a stack, but the height of the tube has to be as least as high as the height of the largest stack of containers, restricting the maximum height of stacks in enclosed spaces
Solution Approach 1:
The load handler is divided into an upper part housing the drive mechanism and a lower part with container-receiving space. The drive mechanism is segmented into wheel assemblies that can be positioned at different heights, allowing the device to access containers at any stack level without requiring the entire device to be as tall as the stack.
Solution Approach 2:
The load handler transitions from a vertical extension approach (rectangular tube reaching up) to a horizontal movement approach (wheel assembly moving laterally above stacks). The drive mechanism moves horizontally along rails positioned above the stacks, eliminating the need for vertical height proportional to stack height.
2Productivity
If the load handler moves laterally above the stacks, then efficient access to containers at any stack level is enabled, but the footprint of the device must be minimized to allow more devices to operate within the same space
Solution Approach 1:
The load handler footprint is segmented to occupy only one grid space, with the upper part extending minimally beyond the lower part. This compact segmentation allows multiple devices to operate in adjacent grid spaces without obstruction, maximizing system density while maintaining rapid retrieval capability.
3Area of moving object
If the upper part houses the drive mechanism, then the footprint of the load handler is reduced, but the lifting capacity and stability must be maintained
Solution Approach 1:
The drive mechanism in the upper part is counterbalanced by positioning the container-receiving space and container mass in the lower part. The container itself acts as a counterweight to the elevated drive mechanism, maintaining overall system balance and stability despite the compact footprint configuration.
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
This design enhances storage system efficiency by allowing more devices to operate within the same space, reducing obstruction and increasing retrieval speed, while maintaining stability and lifting capacity, thus improving overall system performance and storage density.
Implementation Method 1
winch means for lifting a container into the container-receiving space
Implementation Method 2
The load handling device comprises a lower part fitted with wheels to enable lateral movement of the device above the stacks
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A load handling device (100) for lifting and moving containers (106) stacked in a storage system comprising a plurality of rails (22a, 22b) or tracks arranged in a grid pattern above the stacks of containers. The grid pattern comprises a plurality of grid spaces and each stack being located within a footprint of only a single grid space, the load handling device being configured to move laterally on the rails or tracks above the stacks. The load-handling device comprises: a container-receiving space (120) located above the rails or tracks in use and a lifting device (104) arranged to lift a container from a stack into the container-receiving space. One or more wheel lift motors (188) or other wheel lift devices are housed in a vehicle module for raising and lowering one of the sets of wheels (116, 118) with respect to the other set of wheels.