Integrated Vertical Conveyor in Rack Aisle for High-Bay Storage
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Solution Overview
Problem
Existing shelf storage systems face challenges in achieving high throughput and efficient use of available installation space, particularly in high-bay warehouses, due to the limitations of vertical conveyor devices being located outside the shelf-aisle unit and the need for extensive horizontal movement of transport aids.
Innovation Solution
The integration of vertical conveyor devices within the shelf-aisle unit, combined with rail vehicles guided by first and second guide tracks, allows for efficient vertical and horizontal movement of transport aids, enabling more levels to be operated and improving space utilization by eliminating the need for extensive horizontal conveyance outside the unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If vertical conveying devices are arranged outside the rack-aisle unit, then they can be easily accessed and operated, but they occupy excessive installation space and require extensive horizontal movement of transport aids
Solution Approach 1:
The patent merges the vertical conveying devices with the rack-aisle unit by integrating them into the aisle structure. The conveying devices are positioned within the aisle space rather than outside, combining the storage function of the racks with the conveying function of the lifts. This eliminates the need for separate external conveying equipment and reduces the overall footprint while maintaining operational efficiency
Solution Approach 2:
The patent transitions from a two-dimensional arrangement where conveying devices are placed externally at the ends of aisles to a three-dimensional integration where conveying devices are embedded within the aisle volume. This allows vertical conveying to occur within the horizontal aisle space, eliminating the need for additional external space and reducing the horizontal movement path of transport aids
2Adaptability or versatility
If satellite vehicles are used to transfer transport aids during storage or retrieval, then flexibility in material handling is improved, but the complexity of the system increases
Solution Approach 1:
The patent makes the rail vehicles universal by enabling them to perform multiple functions: they transport transport aids horizontally along guide rails, interface with vertical conveying devices for vertical movement, and can operate autonomously or be controlled by a central system. This multi-functionality eliminates the need for separate satellite vehicles while maintaining the flexibility of transferring transport aids between different locations and levels
3Quantity of substance
If more rack levels are operated to increase storage capacity, then storage density improves, but the complexity of vertical conveying operations increases
Solution Approach 1:
The patent segments the vertical conveying function into multiple independent conveying devices distributed at different levels within the aisle. Each conveying device operates independently to serve specific rack levels, allowing the system to handle multiple levels simultaneously without creating a single complex conveying mechanism. This modular approach manages complexity by breaking down the vertical conveying task into simpler, manageable segments
Data Source
Figure 1~2
Figure 1a
Figure 2a
AI summary
The system (1) has rack rows fixed on each other and forming a rack platform in a vertical direction, and a rail vehicle receiving and transporting a transport equipment. Guiding paths guide the rail vehicle and run along a longitudinal direction of a rack alley (18) in the rack platform. A vertical conveyor (28) is arranged in the rack alley or rack platform and integrated with a rack alley unit (20) formed on the rack rows, where the rack alley extends between the rack rows. One of the guiding paths is passed on the vertical conveyor. An independent claim is also included for a method for operating a racking system.