Modular Storage Grid for 3D Robotic Material Handling
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Solution Overview
Problem
Existing automated storage and retrieval systems (AS/RS) are limited by movement constraints imposed by conventional warehouse frame structures, allowing only 2D or 2.5D movements, which hinder the performance of warehouse operations.
Innovation Solution
A system and method for storage and retrieval of materials using a modular, moment frame storage grid composed of interconnected cells, columns, and beams, enabling 3D movement through helical racks and lateral navigation without maneuvering around columns, with modular cells that can be expanded and adapted to various configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional warehouse frame structures are used, then structural simplicity and ease of manufacture are maintained, but movement freedom is limited to 2D or 2.5D only
Solution Approach 1:
The warehouse structure is divided into modular cells that can be independently configured and assembled. Each cell contains columns, beams, and storage racks that can be arranged in different configurations to create various storage densities and access patterns, enabling 3D movement while maintaining structural simplicity through standardization.
Solution Approach 2:
The system transitions from traditional 2D/2.5D movement constraints to full 3D movement capability by introducing vertical stacking of modular cells with multiple storage levels. This allows automated retrieval machines to move freely in all three dimensions (length, width, and height) throughout the warehouse volume, dramatically increasing movement freedom.
2Productivity
If modular cells are added to enable 3D movement, then movement complexity increases, but manufacturing cost decreases
Solution Approach 1:
The warehouse is constructed from standardized modular cells that can be manufactured independently and assembled on-site. These cells use conventional materials (steel beams, columns, and flooring) and standardized connection methods, making them cost-effective while enabling complex 3D configurations that significantly improve warehouse operation performance.
Solution Approach 2:
The modular cells are designed as universal building blocks that can serve multiple functions: structural support, storage accommodation, and movement guidance. The same cell design can be configured for different storage densities, access requirements, and productivity needs, eliminating the need for custom-built structures for each application.
3Adaptability or versatility
If conventional frame structures are used, then construction simplicity is maintained, but adaptability to different configurations is limited
Solution Approach 1:
The frame structure is segmented into standardized modular cells with identical column, beam, and connection component designs. This segmentation allows the same basic structure to be repeated and reconfigured in numerous ways to accommodate different storage requirements, product types, and accessibility needs without increasing overall structural complexity.
Solution Approach 2:
The modular cell design enables dynamic reconfiguration of the warehouse layout as business needs change. Cells can be added, removed, or repositioned to create different storage densities and access patterns, allowing the structure to adapt to varying operational requirements while maintaining the simplicity of the individual cell components.
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 provides enhanced warehouse performance by allowing complex movements, flexible expansion, improved seismic resilience, cost-efficiency, and adaptability, while supporting high weight capacities and enabling precise robotic navigation.
Implementation Method 1
Each column of the frame may have a helical rack wrapped around it, with a corresponding drive mechanism that can rotate the helical rack to enable movement in a third dimension
Data Source
AI summary
A system 100 for automated storage and retrieval of materials can include a storage grid 200, and can include and/or interface with one or more material handling robots 600, and/or any other suitable components. A storage grid 200 can include a set of one or more: cells 300, columns 400, beams 500, and/or any other suitable components.