Hypoxic Pallet Shuttle Storage for Dense Climate-Controlled Racks
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Solution Overview
Problem
Existing offsite storage facilities are expensive, lack scalability, and do not accommodate various item types with different environmental storage requirements, leading to inefficiencies in storage density and operational costs.
Innovation Solution
A fully automated, climate-controlled, and hypoxic storage system with customizable storage modules and a pallet shuttle system that allows for high-density storage by positioning racks closely together without aisles, using a transfer car and shuttle system for efficient retrieval and storage of items in a controlled environment, and maintaining a hypoxic environment to prevent fires and preserve items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If racks are positioned closely together without aisles to increase storage density, then storage density is improved, but ease of operation deteriorates
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system. Robots navigate through narrow aisles between closely positioned racks to retrieve and store items, eliminating the need for wide aisles that would be required for manual access. This substitution of mechanical human operation with automated robotic systems enables high storage density while maintaining operational efficiency.
Solution Approach 2:
The system implements self-service through automated robots that independently navigate, locate, and retrieve items from storage racks. The robots autonomously navigate through narrow aisles using sensors and navigation systems, eliminating the need for human workers to physically access densely packed storage areas. This self-service capability enables close rack positioning while maintaining operational ease through automation.
2Reliability
If climate control is implemented to preserve items, then reliability is improved, but use of energy worsens
Solution Approach 1:
The patent implements localized climate control within individual storage modules or zones rather than uniformly controlling the entire storage facility. Each module can maintain its own temperature and humidity conditions tailored to specific item requirements, reducing the overall energy consumption compared to climate-controlling the entire space. This localized approach preserves item reliability while minimizing energy use by only conditioning air where items are actually stored.
Solution Approach 2:
The storage facility is divided into separate climate-controlled modules or zones that can be independently managed. This segmentation allows the system to maintain preservation conditions only in occupied or critical areas, rather than continuously conditioning the entire facility. Energy consumption is reduced by controlling climate in discrete segments rather than as a monolithic space, while still ensuring item preservation through targeted environmental control.
3Reliability
If fire suppression systems are installed to prevent fires, then reliability is improved, but device complexity worsens
Solution Approach 1:
The patent creates a fire-prevention environment by maintaining controlled atmospheric conditions within storage modules, potentially using inert or low-oxygen atmospheres that inherently prevent fire ignition and propagation. This approach replaces complex active fire suppression systems (sprinklers, detectors, alarms) with a passive fire prevention strategy through environmental control, reducing system complexity while maintaining reliability.
Solution Approach 2:
The system converts the potential harm of fire into a benefit by using controlled atmospheric conditions that prevent fire occurrence. By maintaining specific environmental parameters (low oxygen, controlled temperature, humidity control), the system transforms the storage environment into one that is inherently fire-resistant, eliminating the need for separate fire suppression infrastructure and reducing overall system complexity.
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
The system significantly reduces labor and energy costs, increases storage density, and allows for efficient storage of diverse items with tailored environmental conditions, enhancing preservation and flexibility while minimizing the need for fire suppression systems.
Implementation Method 1
an enclosure enclosing a hypoxic environment
Data Source
AI summary
In one arrangement, a storage system for storing items includes an enclosure enclosing a hypoxic environment, and a pallet shuttle system comprising rows of racks disposed within the hypoxic environment. The pallet shuttle system also includes at least one transfer car and at least one shuttle for carrying storage modules into and out of the racks. The system further includes a loading station outside the hypoxic environment, and an enclosure door to the hypoxic environment. The enclosure door is operable to admit the transfer car of the pallet shuttle system into and out of the hypoxic environment, and to close the hypoxic environment upon passage of the transfer car through the door. Optionally, the system includes paneling separating the enclosure into at least two separately climate-controlled zones such that at least one of the racks is in each of the at least two separately climate-controlled zones.