Grid Rail Load Handler Footprint Reduction
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Solution Overview
Problem
Existing storage systems face inefficiencies in storage density and accessibility, particularly for online retail businesses handling multiple product lines, due to the need for aisle space and limitations in handling multi-product stacks.
Innovation Solution
A load handling device with a reduced footprint that occupies only a single grid space in a storage system, featuring a container-receiving space beneath bulky components and wheels that engage with a grid pattern of rails, allowing lateral movement and efficient retrieval of containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional load handler with a large footprint is used, then it can accommodate bulky components and provide stable lifting, but it occupies multiple grid spaces and reduces storage density
Solution Approach 1:
The patent applies vertical stacking to arrange bulky components (lifting mechanism, control system, power supply) above the container-receiving space rather than horizontally beside it. This dimensional reorganization reduces the horizontal footprint to occupy only a single grid space while maintaining all necessary functional components, thereby increasing storage density without sacrificing manufacturing feasibility
Solution Approach 2:
The patent nests bulky components within a vertically extended housing structure that sits directly above the container-receiving space. The lifting mechanism, control system, and power supply are nested in a compact vertical arrangement, allowing the entire load handler to fit within the vertical envelope of a single grid space while maintaining functional integrity
2Productivity
If more load handling devices are accommodated in the storage system, then retrieval speed increases, but device complexity and space requirements increase
Solution Approach 1:
By transitioning from a horizontal layout to a vertical configuration, the patent enables more load handlers to be positioned along the same horizontal grid line without increasing the overall footprint. Multiple devices can operate in parallel within the same horizontal plane, increasing retrieval speed while maintaining compact space utilization
Solution Approach 2:
The patent segments the load handler into modular components (container-receiving space, lifting mechanism, control system, power supply) that can be independently optimized and arranged. This modular segmentation allows for compact integration and enables multiple devices to be densely packed in the storage system without excessive complexity
3Quantity of substance
If containers are stacked in multi-product stacks, then storage density increases, but accessibility to specific containers becomes more difficult
Solution Approach 1:
The patent extracts the lifting mechanism from the container itself and provides it as a separate, dedicated device positioned above the stack. This external lifting device can selectively engage and extract any container from any position in the stack without requiring other containers to be moved, thereby maintaining high storage density while improving accessibility to specific containers
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A grid frame structure (14), for use in a warehousing environment, in which stackable containers (10) are stacked on top of one another to form stacks (12), the frame structure (14) comprising: a plurality of upright members (16) that support horizontal members (18, 20), the horizontal members (18, 20) comprising a first set of parallel horizontal members (18) being arranged perpendicularly to a second set of parallel horizontal members (20), wherein the upright members (16) and the horizontal members (18, 20) are manufactured from metal, wherein the top level of the frame structure (14) includes rails (22) arranged in a grid pattern across the top of the stacks (12) for supporting robotic load handling devices, the rails (22) including a first set (22a) of parallel rails to guide movement of load handling devices in a first direction (X) across the top of the frame structure and a second set of parallel rails (22b) arranged perpendicular to the first set (22a) to guide movement of load handling devices in a second direction (Y), perpendicular to the first direction, across the top of the frame structure (14); characterised in that: each rail in the first set of rails (22a) comprises two adjacent, longitudinally extending tracks, each track being engageable by wheels of a load handling device; and each rail in the second set of rails (22b) also comprises two adjacent, longitudinally extending tracks, each track being engageable by wheels of a load handling device.