High-Bay Sequencing Rack Layout for Safer Material Changeovers
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Solution Overview
Problem
Existing sequencing processes in high-bay warehouses face issues such as long walking distances, high space requirements, and safety hazards due to overlapping work areas for forklifts and sequencers, with inefficiencies in the sequencing of goods from large load carriers.
Innovation Solution
A racking system with a high-bay warehouse and sequencing levels utilizing lifts and transverse transfer carriages for horizontal and vertical transport, enabling simultaneous delivery and return of large load carriers to alternate sequencing areas without interrupting sequencing, and employing a control unit to manage sequencing orders efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If many large load carriers are provided simultaneously at floor level for sequencing, then the goods can be taken for several sequencing orders, but the walking distance for sequencers between sequencing areas increases significantly
Solution Approach 1:
The system divides the sequencing area into multiple workstations (first and second sequencing areas) arranged in parallel, each capable of independent operation. This segmentation allows sequencers to work at one station while another station handles material delivery, effectively reducing walking distance by distributing sequencing tasks across separated locations rather than requiring all materials to be available at a single centralized location.
Solution Approach 2:
The system pre-delivers large load carriers to sequencing areas using automated lifts and transverse transfer carriages before sequencing operations begin at each workstation. This preliminary action ensures that materials are already in position at multiple separated workstations, eliminating the need for sequencers to walk long distances to retrieve materials during the sequencing process.
2Adaptability or versatility
If many large load carriers are provided simultaneously at floor level, then sequencing for multiple orders is enabled, but the space requirement increases
Solution Approach 1:
The system transitions from horizontal storage of all load carriers at floor level to vertical storage in the high-bay warehouse, utilizing the third dimension (height). Loads are stored vertically on multiple levels and delivered to sequencing areas on demand using lifts and transverse transfer carriages. This dimensional change dramatically reduces the floor space required while maintaining the capability to handle multiple sequencing orders.
Solution Approach 2:
The system pre-positions only the necessary large load carriers at each sequencing area using automated delivery systems, rather than providing all possible load carriers at every location. This preliminary, targeted delivery reduces the space required at each workstation while maintaining versatility through automated retrieval from vertical storage.
3Adaptability or versatility
If sequencing areas are arranged with multiple large load carriers, then various part variants can be provided, but the risk of injury increases due to overlapping work areas for forklifts and sequencers
Solution Approach 1:
The system extracts the material delivery function from the sequencing work area by implementing automated delivery systems (lifts and transverse transfer carriages) that bring large load carriers directly to sequencing areas. This separation removes forklifts and material handling equipment from the sequencer's workspace, eliminating the overlapping work areas that create safety hazards while maintaining access to various part variants through automated retrieval.
Solution Approach 2:
The system introduces automated transverse transfer carriages and lifts as intermediary devices between the vertical storage and sequencing areas. These intermediaries handle all material transport, eliminating the need for forklifts to operate in close proximity to sequencers. The intermediaries provide a safe buffer zone, allowing versatile part variant availability without exposing workers to forklift traffic.
4Length of moving object
If automated lifts and transverse transfer carriages are used for material delivery, then walking distances are reduced, but the device complexity increases
Solution Approach 1:
The automated transport system is segmented into distinct functional modules: vertical lifts for elevation changes and transverse transfer carriages for horizontal movement. This modular segmentation allows each component to be independently controlled and maintained, reducing overall system complexity despite the automation. The segmented architecture enables straightforward integration with existing warehouse infrastructure while achieving the goal of reduced walking distances through coordinated automated delivery to multiple sequencing areas.
Data Source
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AI summary
A racking system for sequencing goods from a high-bay warehouse (1) into sequencing racks (2), comprising a high-bay warehouse (1) with at least one sequencing level (EO), in particular at ground level, and several storage levels (E1,.., E5), wherein large load carriers (3) are stored at storage locations in the storage levels (E1,.., E5) during normal operation of the racking system, each containing goods of one type, wherein a lift (4) for vertical transport of the large load carriers (3) is arranged in the high-bay warehouse (1), wherein the racking system includes at least one transverse transfer carriage (5) for horizontal transport of the large load carriers (3) in each storage level (E1,.., E5), wherein the racking system includes a control unit, wherein the control unit is configured to process sequencing orders such that the required large load carriers (3) for a sequencing order are retrieved from the storage levels (E1,.., E5) are delivered to at least a second sequencing area (S2) in the sequencing level (EO), while goods from the required large load carriers (3) for another sequencing order in a first sequencing area (S1) in the sequencing level (EO) are placed into a sequencing rack (2) of the first sequencing area (S1) and vice versa.