Grid Service Robot for In-Line Maintenance and Rescue
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Solution Overview
Problem
Existing robotic bin handling systems require manual intervention for maintenance and cleaning of load handling devices and grids, necessitating the shutdown of the entire system, which is inefficient and costly, especially in large-scale operations.
Innovation Solution
A robotic service device with wheels that can engage with perpendicular rails, allowing it to move independently on a grid and interact with load handling devices for maintenance, cleaning, and fault diagnosis, thereby isolating and relocating faulty devices without shutting down the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used for maintenance and cleaning of load handling devices and grids, then the system can be maintained and cleaned effectively, but the entire system must be shut down, causing downtime and reduced productivity
Solution Approach 1:
The service device is an autonomous robotic system that performs maintenance and cleaning operations independently without requiring human operators. It navigates the grid autonomously, identifies load handling devices requiring service, and executes cleaning or maintenance tasks automatically, enabling the system to service itself without external intervention
Solution Approach 2:
The service device performs maintenance and cleaning operations proactively before faults occur or escalate. By continuously monitoring and servicing load handling devices during normal operations, it prevents breakdowns and maintains optimal system performance, rather than reacting to failures after they occur
2Ease of repair
If the entire system is shut down for maintenance, then all load handling devices can be serviced, but system downtime increases and operational efficiency decreases
Solution Approach 1:
The service device enables continuous maintenance operations during normal system operation. Load handling devices are serviced individually or in small groups while the rest of the system continues to operate, maintaining continuous productive action without interruption. The service device works concurrently with load handling operations, performing maintenance in between cycles rather than requiring system-wide shutdown
Solution Approach 2:
The maintenance system is segmented into independent service units that can target specific load handling devices individually. Rather than servicing the entire system as a monolithic unit requiring complete shutdown, the service device can isolate and service individual load handlers or specific grid sections, allowing other parts of the system to continue operating unaffected
3Reliability
If a robotic service device is introduced to enable automated maintenance, then system reliability improves and downtime reduces, but device complexity increases
Solution Approach 1:
The service device is designed as a multi-functional platform that performs multiple maintenance tasks including cleaning, fault diagnosis, and repair operations on various load handling devices. This universal design consolidates what would otherwise require multiple specialized devices into a single versatile unit, reducing overall system complexity while maintaining comprehensive maintenance capabilities
Solution Approach 2:
The service device acts as an intermediary between the load handling devices and the central control system. It interfaces with load handlers to diagnose faults and perform repairs, while communicating status and requirements to the control system, simplifying the overall architecture by providing a dedicated maintenance layer rather than requiring direct control system involvement in all maintenance operations
Data Source
AI summary
A robotic service device is described for use on a robotic picking system grid. The robotic service device is capable of driving to any location on the grid order to perform maintenance operations or cleaning. Additionally, the service device may be used to rescue robotic load handling devices operational in the picking system. The robotic service device may include a releasable docking mechanism to enable it to dock and latch on to malfunctioning load handling devices. The service device may also be provided with cleaning capability and a camera to enable the condition of the grid and other robotic devices to be monitored.