Grid-Rail Load Handler for Dense Container Stack Retrieval
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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 aisles and are not well-suited for selecting single containers from multi-product stacks, especially in enclosed spaces like warehouses.
Innovation Solution
A load-handling device designed to occupy a single grid space in a storage system, featuring a compact footprint with wheels guided by rails for two-dimensional movement, a winch mechanism for lifting containers, and a gripper device that can engage with containers from above, allowing for efficient retrieval and movement of containers from any stack level without obstructing other devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a load handler uses a rectangular tube as high as the largest stack of containers to extract containers in a single operation, then containers can be retrieved from any stack level, but the device occupies excessive vertical space and cannot operate in enclosed warehouses
Solution Approach 1:
The load handler is divided into separate functional modules: a base unit with drive wheels for lateral movement, and a detachable lifting assembly with gripper that can be positioned independently. This segmentation allows the lifting mechanism to access containers at any height without requiring the entire device to be as tall as the container stack.
Solution Approach 2:
The invention transitions from vertical access (requiring tall equipment) to horizontal access by positioning the base unit laterally adjacent to the container stack. The lifting assembly extends vertically only when needed for gripping, rather than the entire device maintaining a tall profile throughout operation.
2Productivity
If multiple load handlers operate simultaneously in a storage system, then retrieval speed and productivity improve, but device footprint and space requirements increase
Solution Approach 1:
Multiple load handlers are merged into a compact configuration where the base unit and lifting assembly work in close proximity. This integrated design reduces the overall footprint compared to distributed separate components, enabling multiple units to operate simultaneously in limited space.
Solution Approach 2:
The load handler employs dynamic positioning where the lifting assembly can be extended and retracted as needed, and the base unit moves laterally to access different container positions. This dynamic operation reduces the static footprint requirement, allowing multiple devices to share the same workspace efficiently.
3Ease of operation
If storage systems use aisles between rows of shelves for product access, then operatives can retrieve products, but storage density decreases due to wasted aisle space
Solution Approach 1:
The invention replaces the mechanical aisle-based access system with an automated robotic load handler that uses sensor-based navigation and computer-controlled positioning. This substitution eliminates the need for physical aisles, as the robotic system can precisely locate and access containers in densely packed configurations without requiring human-operated walkways.
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 solution enhances storage system efficiency by reducing device footprint, enabling more devices to operate simultaneously, and improving retrieval speed by allowing access to containers at any stack level, thus optimizing storage density and accessibility.
Implementation Method 1
a winch mechanism (150, 151) for lifting the container (106)
Implementation Method 2
a gripper device (110) configured to engage with the container (106) from above
Implementation Method 3
wheels guided by rails for two-dimensional movement
Data Source
Figure 1
Figure 2
Figure 3a
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 (22a, 22b) arranged in a grid pattern (14) above the stacks of containers. The grid pattern comprises 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 comprises a mechanism for enabling lateral movement of the device in one of two transverse directions by enabling either a first or second set of wheels to selectively engage the first or second set of rails or tracks (22a or 22b).