Hybrid Storage System with AMR and Shuttle Segmentation
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Solution Overview
Problem
Traditional automated storage and retrieval systems (ASRS) have limited flexibility and scalability, leading to suboptimal storage density and throughput, while two-dimensional pallet shuttle systems are costly and inefficient for order consolidation and sequencing.
Innovation Solution
A hybrid system combining ground floor order fulfillment with autonomous mobile robots (AMR) or automated guided vehicles (AGV) for fast mover storage and elevated multilevel racking with two-directional load carrying shuttles for slow movers, connected by vertical handling means, allowing flexible and efficient storage and retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional ASRS with fixed infrastructure is used, then storage capacity is improved, but flexibility and scalability are reduced
Solution Approach 1:
The system divides storage into multiple levels (ground floor and elevated storage areas) with different access methods. Each level serves specific functions: ground floor for fast movers with AMR/AGV access, and elevated levels for slow movers with 2D shuttle access. This segmentation allows each zone to be optimized independently, maintaining flexibility while achieving high storage capacity.
Solution Approach 2:
The system transitions from traditional single-level ASRS to multi-level storage with vertical separation of functions. By utilizing vertical space for slow mover storage and maintaining ground floor for fast movers, the system achieves high storage density without compromising accessibility or flexibility of the ground floor area.
2Quantity of substance
If traditional ASRS with fixed infrastructure is used, then storage density is improved, but throughput is reduced
Solution Approach 1:
The system segments storage and retrieval operations into two distinct pathways: fast movers on ground floor accessed by AMR/AGV for high throughput, and slow movers on elevated levels accessed by 2D shuttles for high density. This segmentation allows each subsystem to optimize for its specific function without compromising the other.
Solution Approach 2:
The ground floor storage area acts as an intermediary buffer between elevated storage and order fulfillment. Fast movers are stored and retrieved on ground floor, while slow movers are transferred from elevated storage to ground floor buffer before final retrieval, enabling efficient order consolidation and sequencing.
3Quantity of substance
If 2D pallet shuttles are used for all storage, then storage density is improved, but cost and complexity increase
Solution Approach 1:
The system applies different storage and access solutions to different locations based on local requirements. Elevated storage areas with slow mover demand use 2D shuttles for high density, while ground floor areas with fast mover demand use simple open storage with AMR/AGV access. This local optimization reduces overall system complexity while maintaining high storage density where needed.
4Quantity of substance
If 2D pallet shuttles are used for order consolidation, then storage capacity is improved, but speed and efficiency are reduced
Solution Approach 1:
The system segments order fulfillment into two streams: fast movers consolidated and shipped directly from ground floor storage, and slow movers first transferred to ground floor buffer area for consolidation and sequencing. This segmentation eliminates the need for slow 2D shuttle operations during order consolidation, significantly improving speed while maintaining storage capacity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly improves throughput and storage density by reducing vertical movements and costs, enabling flexible use of space and efficient order consolidation and sequencing.
Implementation Method 1
a two-directional load carrying shuttle (9) adapted to travel on both of said storage tracks (8) and said aisle tracks (5)
Implementation Method 2
the ground floor order fulfilment area (A) and ground floor storage area (2) being serviced by autonomous mobile robots (AMR) (10) and/or automated guided vehicles (AGV)
Implementation Method 3
allowing access to unit loads in any location from all four directions. This significantly reduces the amount of shuttling and shuffling. Further the rack structure is not needed or used for ground floor based storage
Data Source
Figure 1
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Figure 3
AI summary
Order fulfillment system (1) with a ground floor order fulfilment area and a storage system for unit loads, the storage system having a ground floor storage area (2) and an elevated storage area (3), wherein the elevated storage area is a multilevel racking (4) having aisle tracks between the racks in every level and the racks having storage channels having storage tracks in every level, the aisle tracks and storage tracks being serviced by a two-directional load carrying shuttle (9) adapted to travel on both said storage tracks and said aisle tracks for storage and retrieval of unit loads, wherein the ground floor order fulfilment area and ground floor storage area are serviced by autonomous mobile robots (AMR) (10) and/or automated guided vehicles (AGV) under the control of a control.