Modular structure for an automated storage and retrieval system
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Solution Overview
Problem
Traditional automated order fulfillment systems require time-consuming and labor-intensive assembly of individual components, hindering quick and efficient construction of structures needed for growing demand in automated facilities.
Innovation Solution
The development of modular storage structures with registration features on tie beams and plates allows for accurate and rapid assembly of shelf and tower modules, enabling efficient and precise spacing for mobile robot navigation and inventory access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual components are assembled one piece at a time using traditional stick-built structures, then the structure can be built with flexibility, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
The structure is divided into modular components (vertical rails, horizontal rails, tie beams, tie plates) that can be pre-assembled into complete levels. Each level module can be independently fabricated and then quickly installed as a complete unit, combining the flexibility of modular assembly with reduced on-site labor time.
Solution Approach 2:
Complete levels are pre-assembled in a controlled environment before installation. The horizontal rails, vertical rails, tie beams, and tie plates are configured and secured together in advance, allowing for quality control and reducing the complexity of on-site assembly operations.
2Reliability
If traditional stick-built assembly methods are used, then individual components can be adjusted, but numerous time-consuming adjustments are required for reliable mobile robot operation
Solution Approach 1:
Mechanical adjustments are replaced with precision-engineered registration features (pins, holes, slots) that automatically ensure correct positioning. The tie beams and tie plates incorporate these registration features that mechanically guarantee proper spacing and alignment when assembled, eliminating the need for time-consuming manual adjustments.
Solution Approach 2:
The design specifies fixed, predetermined spacing parameters between shelves based on mobile robot requirements. By establishing these parameters in the design phase and incorporating them into the modular components with registration features, the system ensures reliable robot operation without requiring field adjustments.
3Productivity
If modular storage structures with registration features are used, then assembly speed and accuracy are improved, but the device complexity increases
Solution Approach 1:
The structure is divided into modular components (vertical rails, horizontal rails, tie beams, tie plates) that can be pre-assembled into complete levels. Each level module can be independently fabricated and then quickly installed as a complete unit, combining the flexibility of modular assembly with reduced on-site labor time.
Solution Approach 2:
The tie beams and tie plates serve multiple functions: they connect vertical and horizontal rails, provide registration features for precise positioning, establish correct spacing between shelves, and enable quick assembly through standardized interfaces. This multi-functionality reduces the need for separate adjustment mechanisms.
Data Source
AI summary
An automated system structure may be quickly and efficiently assembled using a number of storage modules. Storage modules may be comprised of a pair of shelf modules, each comprising a number of defined storage locations for storing totes, cartons, trays or other containers. The shelf modules may themselves be modular units comprising a number of horizontal storage levels affixed to a pair of vertical support assemblies at each end of the shelf modules. The pair of shelf modules may be accurately spaced from each other by mounting the shelf modules to tie beams at the bottom and tie plates at the top.