Horizontal Tote Rows for High-Density Automated Retrieval
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Solution Overview
Problem
Existing automated storage and retrieval systems 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 of any tote within the row.
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 arrangement of totes. Instead of stacking totes vertically where retrieval requires lifting from the top, the system arranges totes in horizontal rows that can be accessed from the side, enabling retrieval of any tote in the row without moving others, thus maintaining high density while improving retrieval speed.
Solution Approach 2:
The system divides the storage structure into multiple independent horizontal rows, each row accessible as a separate unit. This segmentation allows parallel access to different rows and enables the retrieval mechanism to work on individual rows independently, improving overall system throughput and retrieval efficiency.
2Adaptability or versatility
If carriers move between aisles of products to access totes, then product variety and accessibility are improved, but storage density decreases due to space required for carrier movement
Solution Approach 1:
The patent merges the carrier movement function with the tote retrieval function by integrating the carrier directly into the row structure. The carrier travels along the side of each row and can access any tote in that row, eliminating the need for separate aisle spaces and combining storage with retrieval capabilities in a compact configuration.
Solution Approach 2:
The system introduces an intermediary carrier mechanism that travels along the exterior of each row, serving as a mediator between the retrieval system and the totes. This carrier can stop at any position along the row, extract the desired tote, and return it, providing flexible access without requiring physical aisles between rows.
3Productivity
If totes are arranged in horizontal rows and mechanically coupled, then retrieval speed is improved for any tote in the row, but device complexity increases due to coupling mechanisms
Solution Approach 1:
The coupling mechanism is designed to be self-actuating through the natural motion of tote insertion and removal. When a tote is inserted into a row, its weight and positioning automatically engage the coupling mechanism with adjacent totes. When a tote is removed, the coupling automatically disengages, eliminating the need for complex active control systems.
Solution Approach 2:
The patent replaces complex active mechanical coupling systems with passive mechanical interlocks that rely on gravity and simple geometric constraints. The coupling mechanism uses the tote's own weight and positioning to engage and disengage connections, substituting complex controlled mechanical systems with simpler passive mechanical designs.
Data Source
AI summary
A high-density storage system for goods is described in which totes carrying the goods are storage in a storage structure and stored and retrieved by robotic carriers. The carriers move laterally and/or longitudinally along the exterior of the support structure and retrieve totes from the interior of the structure by manipulating rows of coupled totes. Totes at the ends of rows are quickly removed and stored in another row until the desired tote appears at the end of the row, at which point the carrier proceeds with the tote to the exit point of the storage system. Storing totes is also a quick action by pushing them into any row. As a tote is pushed into the row, it will automatically couple with a tote inside the row that it comes into contact with.