Grid-Rail Load Handler With Vertical Lift for Dense Stack Access
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Solution Overview
Problem
Existing load handling systems for stacked containers in storage systems face inefficiencies due to high space requirements and limited access to containers within multi-product stacks, particularly in high-density storage environments where tens of thousands of different product lines need to be efficiently stored and retrieved.
Innovation Solution
A load handling device with a reduced footprint, featuring a grid-pattern rail system and a lifting mechanism with a gripper device that can selectively engage with containers from above, allowing lateral movement and vertical lifting of containers within a single grid space, thereby optimizing storage density and access efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If free-standing stacks of containers are arranged in rows to reduce storage volume, then storage density is improved, but access to specific containers requires complicated hoisting mechanisms that increase device complexity and cost
Solution Approach 1:
The patent extracts the lifting function from a complex centralized hoisting mechanism and relocates it to individual load handling devices. Each load handler has its own lifting mechanism, eliminating the need for complicated overhead hoisting systems while maintaining the ability to access containers at any height in the stack.
Solution Approach 2:
The system segments the storage and retrieval operations by assigning individual load handling devices to specific stacks. Each device operates independently with its own lifting mechanism, simplifying the overall system architecture while enabling parallel operations across multiple stacks.
2Productivity
If the load handler tube height is made at least as high as the largest stack to extract containers in single operation, then retrieval efficiency is improved, but the maximum stack height is restricted by the enclosed space available
Solution Approach 1:
The load handling device employs a dynamic lifting mechanism where the tube can extend vertically to match the height of any stack it needs to service. This dynamic adjustment allows the system to maintain high retrieval efficiency while adapting to varying stack heights within the available enclosed space.
Solution Approach 2:
The system resolves the height constraint by allowing the load handler tube to extend in the vertical dimension as needed, rather than requiring the entire tube to be as tall as the maximum stack from the outset. This dimensional flexibility enables efficient container retrieval without restricting stack height.
3Productivity
If single-product stacks are used to simplify container handling, then storage and retrieval efficiency is improved, but a very large floor area is required to accommodate all stacks for tens of thousands of product lines
Solution Approach 1:
The load handling device is designed as a universal system that can efficiently handle both single-product stacks and multi-product stacks. The device's ability to selectively grip and lift containers from any position in a stack makes it equally effective for homogeneous and heterogeneous container arrangements, eliminating the need for separate single-product stack systems.
Solution Approach 2:
The system segments the storage organization by allowing multi-product stacks to be divided into smaller sub-stacks or groups that can be independently managed. This segmentation enables efficient retrieval from multi-product stacks while reducing the total number of stacks required, thereby minimizing floor area usage.
4Productivity
If more load handling devices are deployed to increase retrieval speed, then productivity is improved, but device footprint increases causing more obstruction in the storage system
Solution Approach 1:
The patent extracts the lifting function from a large centralized structure and places it in compact load handling devices with small footprints. This extraction allows multiple devices to operate simultaneously in the same storage space without significant obstruction, enabling parallel operations that increase overall retrieval speed.
Data Source
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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).