Load Handler Layout for Single-Space Container Retrieval
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Solution Overview
Problem
Existing load handling systems for dense storage of diverse products face inefficiencies due to high space requirements and limited accessibility, especially in enclosed spaces, as they often rely on single-product stacks and complex hoisting mechanisms, which are impractical for online retail and high-volume storage needs.
Innovation Solution
A load handling device with a reduced footprint, featuring a vehicle module with bulky components housed above the container-receiving space, allowing for efficient two-dimensional movement and improved accessibility by using a set of wheels and a crane device with a gripper plate, enabling the device to operate within a single stack space and accommodate multiple devices without obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rectangular tube load handler is used to grip containers at any level in the stack, then containers can be lifted at once from a stack, but the height of the tube has to be at least as high as the height of the largest stack of containers, restricting the maximum height of stacks in enclosed spaces
Solution Approach 1:
The load handler is divided into two separate functional modules: a vehicle module for horizontal movement and a container receiving space for vertical container handling. This segmentation allows the container receiving space to be positioned directly above the vehicle module, eliminating the need for a tall rectangular tube structure while maintaining the ability to extract containers from any stack height.
Solution Approach 2:
The invention transitions from a vertical extension approach (rectangular tube matching stack height) to a horizontal positioning approach (vehicle module moving along rails). By solving the container access problem in the horizontal plane rather than extending vertically, the system enables container extraction from stacks of any height without increasing the handler's vertical dimension.
2Ease of manufacture
If bulky components are housed in a vehicle module to one side of the container-receiving space, then the load handling device can operate, but it occupies the space above two stacks of containers, reducing system efficiency
Solution Approach 1:
The vehicle module and container receiving space are merged into a vertically stacked configuration where the container receiving space is positioned directly above the vehicle module. This merging consolidates the device's footprint to occupy only one stack space horizontally, allowing multiple devices to operate simultaneously without obstruction and improving overall system efficiency.
3Productivity
If single-product stacks are used to store diverse products, then containers can be efficiently moved between stacks, but a very large floor area would be required to accommodate all stacks required for online retail
Solution Approach 1:
The load handling device is designed with universal functionality to handle diverse products through multi-product stacks. The device can efficiently retrieve any container from any position in the stack regardless of product type, enabling the use of multi-product stacks that store diverse items vertically. This eliminates the need for separate single-product stacks for each product line, dramatically reducing the floor area required while maintaining container movement efficiency.
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 design enhances storage system efficiency by allowing more devices to operate simultaneously, reducing the footprint, and improving accessibility and stability, enabling efficient retrieval and storage of diverse products in high-density environments.
Implementation Method 1
a set of wheels arranged around a periphery of the container-receiving space
Implementation Method 2
The load handling device is equipped with a set of wheels arranged around a periphery of the container-receiving space
Implementation Method 3
a crane device with a gripper plate, enabling the device to operate within a single stack space
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A load handling device (100) for lifting and moving containers (106) stacked in a storage system comprising a plurality of rails or tracks arranged in a grid pattern above the stacks of containers. The load handling device is configured to move laterally on the rails or tracks above the stacks. The load-handling device comprises a container-receiving space(120) into which the container may be lifted. The container-receiving space is arranged beneath a vehicle module (112). The vehicle module houses a battery (156) to power motors (152,154), controllers, sensors and other components.