High-Density Tote Storage With Horizontal Row Retrieval
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Solution Overview
Problem
Existing automated storage and retrieval systems (AS/RS) face limitations in storage density and retrieval efficiency, particularly when carriers move between aisles or vertically stack totes, leading to reduced performance and longer retrieval times for totes buried deep in stacks.
Innovation Solution
Totes are arranged in horizontal rows within a supporting structure, mechanically coupled to allow for simultaneous retrieval by pulling or pushing the outer tote, which in turn pulls or pushes all connected totes, enabling efficient storage and retrieval by decoupling totes from one row and coupling them to another.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If totes are stacked vertically to maximize storage density, then storage density is improved, but retrieval time increases for totes buried lower in the stacks
Solution Approach 1:
The patent transitions from vertical stacking to horizontal row-based storage, changing the primary dimension of organization. Totes are arranged in horizontal rows within a supporting structure, allowing carriers to access any tote in the row by moving horizontally along the row rather than vertically through stacks. This dimensional change enables rapid retrieval of any tote regardless of its position in the row.
2Adaptability or versatility
If carriers move between aisles of products to retrieve totes, then retrieval flexibility is improved, but the space required for carrier movement reduces overall storage density
Solution Approach 1:
The patent merges the storage structure with the carrier movement system by integrating horizontal carrier tracks directly within the supporting structure that holds the totes. The carriers move along rails that are part of the same structure providing tote support, eliminating the need for separate aisle spaces. This integration allows carriers to access totes directly at their storage locations without traversing separate aisles.
3Speed
If totes are arranged in horizontal rows, then retrieval speed is improved for any tote in the row, but the number of totes per row is limited by structure width
Solution Approach 1:
The patent implements multiple horizontal rows of totes nested within vertical bays of the supporting structure. Each bay contains several rows stacked vertically, creating a nested arrangement where rows are nested within bays. This nested configuration allows the system to accommodate many totes per row while maintaining compact vertical organization, effectively overcoming the width limitation by utilizing vertical space within each bay.
Data Source
AI summary
A high-density storage system for goods is described in which totes carrying the goods are stored in a storage structure and stored and retrieved via stationary or mobile conveyors running along opposite ends of each layer of the storage structure. The totes may be moved to or from the conveyors as the rows move at a constant velocity toward or away from the conveyors. Totes at the ends of rows are quickly moved and stored in another row until the desired tote appears at the end of the row, at which point the desired tote is carried to an exit point of the storage structure by one of the conveyors.