Individual Case Storage and Retrieval with Multilevel Conveyors
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Solution Overview
Problem
Conventional warehousing systems, including automated systems, are inefficient in handling mixed pallets of different goods and do not allow for the retrieval of individual case units without transporting entire carriers or pallets to a workstation.
Innovation Solution
A storage and retrieval system utilizing multilevel vertical conveyors and autonomous transport robots to efficiently store and retrieve individual case units directly, without containers, allowing for dynamic allocation of storage space and flexible access to any storage location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If case units are stored in carriers or on pallets, then storage density is improved, but retrieval of individual case units requires transporting entire carriers or pallets, increasing time and operational complexity
Solution Approach 1:
The system segments the storage and retrieval process by allowing individual case units to be stored in dedicated slots within carriers, enabling selective retrieval of single case units without moving entire carriers or pallets. The robotic system can access and retrieve individual case units from carrier slots, dividing the retrieval operation into unit-level precision rather than carrier-level bulk operations.
Solution Approach 2:
The invention extracts the ability to retrieve individual case units from the constraint of moving entire carriers or pallets. By implementing robotic systems with end effectors that can grasp and manipulate individual case units, the system takes out the unnecessary movement of carrier containers, allowing direct access to and retrieval of single case units while carriers remain in place.
2Extent of automation
If conventional automated warehousing systems are used, then automation level is improved, but handling of mixed pallets with different goods types becomes inefficient
Solution Approach 1:
The system implements dynamic adaptability through robotic systems that can adjust their behavior based on the specific configuration of mixed pallets. The robotic end effectors and control systems dynamically adapt to different case unit sizes, shapes, and positions, allowing efficient handling of mixed pallets with varying goods types without requiring fixed, pre-programmed operations for each product configuration.
Solution Approach 2:
The invention utilizes parameter changes by allowing the robotic system to modify operational parameters such as grasp force, movement speed, and positioning precision based on the detected characteristics of individual case units. This enables the automated system to efficiently handle diverse mixed pallet contents by adjusting parameters in real-time according to the specific goods being manipulated.
3Ease of operation
If entire carriers or pallets are transported to workstations for case unit removal, then individual case unit access is achieved, but operational complexity and energy consumption increase
Solution Approach 1:
The system extracts the unnecessary step of transporting entire carriers or pallets to workstations by implementing robotic end effectors that can directly access and retrieve individual case units from their storage locations. This eliminates the energy-consuming bulk transport operation while maintaining the capability for individual case unit access.
Solution Approach 2:
The robotic system performs self-service by autonomously navigating to storage locations, grasping individual case units, and delivering them to designated destinations without requiring the intermediate step of moving entire carriers or pallets to fixed workstations. The system serves itself by integrating storage access and case unit retrieval into a single optimized operation.
Data Source
AI summary
A storage and retrieval system including a vertical array of storage levels, each storage level having, picking aisles, storage locations, disposed within the picking aisles, and at least one transfer deck providing access to the picking aisles, a multilevel vertical conveyor system configured to transport the uncontained case units to and from the vertical array of storage levels, each storage level being configured to receive uncontained case units from the multilevel vertical conveyor system, at least one autonomous transport located on each storage level for transporting the uncontained case units between respective storage locations and the multilevel vertical conveyor system, and a controller configured to create a primary access path through the transfer decks and picking aisles to a predetermined one of the storage locations and at least one secondary access path to the predetermined one of the storage locations when the primary path is impassable.