Modular Conveyor Storage System Horizontal Expansion
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Solution Overview
Problem
Existing storage and conveyor systems require high ceiling clearance for vertical storage, limiting facility choices and efficiency, as they can only move one material position at a time, leading to inefficiencies in material exchange and handling, especially in manufacturing contexts like metal laser processing.
Innovation Solution
The Modular Conveyor and Storage System (MCSS) employs horizontal storage with a layered section and elevator-mounted conveyors for bidirectional reciprocating motion, allowing multiple pallets to move simultaneously, eliminating the need for high ceiling clearance and increasing storage capacity by expanding horizontally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If vertical storage systems are used, then storage capacity is increased by utilizing vertical space, but ceiling height requirements limit facility choices and installation locations
Solution Approach 1:
The patent transitions from vertical storage (utilizing height dimension) to horizontal storage (utilizing floor plane dimensions). The conveyor system stores materials on horizontal racks at multiple levels accessible through bidirectional conveyor loops, converting vertical space requirements into horizontal footprint requirements, thereby eliminating ceiling height constraints while maintaining storage capacity.
2Device complexity
If vertical storage systems move one material position at a time, then system complexity is reduced, but material exchange cycle times increase significantly
Solution Approach 1:
The storage system is divided into multiple independent rack levels (at least two levels) with separate conveyor loops for each level. Each level can operate independently with its own bidirectional conveyor, allowing parallel material movement across different levels. This segmentation enables multiple pallets to be moved simultaneously across different levels, dramatically reducing material exchange cycle times while maintaining manageable system complexity through modular design.
Solution Approach 2:
The bidirectional conveyor loops enable continuous material circulation without idle return trips. Materials can be conveyed in either direction along closed loops, allowing the system to maintain continuous productive action by immediately utilizing conveyor capacity in the optimal direction rather than waiting for single-direction cycles to complete.
3Productivity
If horizontal storage with bidirectional conveyors is implemented, then material exchange efficiency is improved by moving multiple pallets simultaneously, but system complexity increases
Solution Approach 1:
The conveyor loops serve multiple functions: they act as both storage access pathways and material transfer mechanisms. The same bidirectional conveyor infrastructure enables materials to be moved between different rack levels, positioned at various discharge points, and circulated continuously. This multi-functionality reduces the need for separate specialized conveyors for each operation, managing overall system complexity while achieving high productivity through coordinated multi-level operations.
Data Source
AI summary
A modular system for material storage and conveying having a layered storage section with two or more storage layers having conveyors, the layered storage section being associated with a load section and a delivery section having their own conveyors at each end of the layered storage section, and elevators that can selectively position the load and delivery section at operational heights of the conveyors of the layered storage section.