Grid Robot Battery Exchange for Continuous ASRS Operation
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Solution Overview
Problem
Existing automated storage and retrieval systems face issues with robot standstill due to the need for recharging, reducing operational cycles to 16 hours per day, and existing power supply arrangements compromise space and stability while being complex and prone to failure.
Innovation Solution
An automated storage and retrieval system with a replaceable power supply compartment in the container handling vehicle, supported by a charging station with a power supply support and locking mechanism, allowing efficient and stable power exchange without reducing storage space or vehicle stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed power supply is integrated into the container handling vehicle, then the vehicle structure is simplified, but the operational cycle is reduced to 16 hours per day due to recharging standstill
Solution Approach 1:
The power supply system is segmented into a fixed power supply unit integrated into the vehicle and a removable battery pack. This segmentation allows the battery pack to be quickly exchanged at charging stations without requiring the vehicle to stop for recharging, thereby maintaining operational continuity while keeping the vehicle structure relatively simple.
Solution Approach 2:
Battery packs are pre-charged at charging stations before being installed on vehicles. This preliminary action ensures that vehicles always have charged power supplies available, eliminating standstill time during operation and maintaining high productivity without complicating the vehicle's integrated power system.
2Stability of the object's composition
If a power supply support structure is added to the charging station, then the power exchange stability is improved, but the device complexity increases
Solution Approach 1:
The power supply support structure incorporates a locking mechanism that uses mechanical counterforces to secure the battery pack during exchange. This locking mechanism compensates for the weight and dimensions of the battery pack, ensuring stable power exchange without requiring overly complex support structures.
Solution Approach 2:
A power supply support structure acts as an intermediary between the charging station and the battery pack. This intermediate component facilitates stable power exchange by providing a dedicated interface with locking mechanisms, while keeping the overall charging station design relatively simple and modular.
3Speed
If the power supply compartment opening faces the movement direction, then the power exchange speed is improved, but the vehicle stability is compromised
Solution Approach 1:
The power supply compartment is designed with an asymmetric opening that faces the movement direction for quick access, while the internal battery pack orientation and locking mechanism are asymmetrically configured to maintain vehicle stability. This asymmetric design allows fast power exchange while preserving structural balance during operation.
Solution Approach 2:
The power supply compartment opening faces the movement direction (horizontal dimension) for rapid access, while the battery pack insertion and locking occur in a different dimensional plane. This multi-dimensional approach enables fast power exchange without compromising vehicle stability in the vertical and lateral dimensions.
4Reliability
If a locking mechanism is added to the power supply support, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The locking mechanism is extracted as a separate, modular component of the power supply support structure rather than being integrated into the main charging station. This extraction allows for a simple, reliable locking function without adding overall system complexity, as the locking mechanism can be independently designed and maintained.
Solution Approach 2:
The locking mechanism is designed as a simple, straightforward mechanical component that prioritizes reliability over complexity. By using a basic locking design rather than a complex electronic system, the connection reliability is improved while keeping the overall device complexity low and maintenance requirements minimal.
Data Source
Figure 1
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Figure 4~5
AI summary
The present invention provides an automated storage and retrieval system (1) comprising: a track system (108) comprising a first set of parallel tracks (110) arranged in a horizontal plane (P) and extending in a first direction (X), and a second set of parallel tracks (111) arranged in the horizontal plane (P) and extending in a second direction (Y) which is orthogonal to the first direction (X), said first and second sets of tracks (110, 110) forming a grid pattern in the horizontal plane (P) comprising a plurality of adjacent grid cells (122), each grid cell comprising a grid opening (115) defined by a pair of adjacent tracks (110a, 110b) of the first set of tracks (110) and a pair of adjacent tracks (111a, 111b) of the second set of tracks (111); a plurality of storage columns (105) located beneath the track system (108), wherein each storage column (105) is located vertically below a grid opening (115) and arranged to store a stack (107) of storage containers (106); a container handling vehicle (3-5) for lifting at least one storage container (106) stacked in the stacks (107), the container handling vehicle (3-5) being configured to move laterally on the track system (108) above the storage columns (105) to access the storage containers (106) via the grid openings (115), wherein the container handling vehicle (3-5) comprises a lower part (17a) comprising at least one storage compartment (24) for storing a storage container (106), an upper part (17b) arranged vertically above the lower part (17a), rolling means (18) for guiding the container handling vehicle (3-5) along the track system (108), and a power supply compartment (27a) for accommodating a replaceable power supply (28), wherein the power supply compartment (27a) is arranged in the upper part (17b) of the container handling vehicle (3-5) and is configured to receive the replaceable power supply (28) via an opening facing towards the first direction (X) or the second direction (Y); a replaceable power supply (28) for accommodation in the power supply compartment, having a power supply charging connection (46); and a charging station (40) for charging of the replaceable power supply (28), the charging station (40) comprising a charging connection (45) configured to create an electrical connection with the power supply charging connection (46) and a power supply support (43) for releasably supporting the power supply (28) during charging; wherein the power supply locking assembly (27,27b,27c) is moveable between a first position, in which the power supply locking assembly may hold the power supply in place, and a second position wherein the power supply may be moved, and the power supply locking assembly (27, 27b, 27c) is locked in the first position by a releasable locking mechanism (50), wherein the power supply support (43) is arranged to interact with the releasable locking mechanism (50) and/or the power supply locking assembly (27,27b,27c), such that the power supply locking assembly may move into the second position when the power supply support (43) is extended into the power supply compartment (27a) to retrieve a discharged power supply or insert a charged power supply. Also provided is such a container handling vehicle, and a method of charging a power supply accommodated within a power supply compartment of such a container handling vehicle.