Movable Track Vehicle Handling for Dense Storage Throughput
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Solution Overview
Problem
Modern material handling systems face challenges in efficiently utilizing resources such as space, equipment, and manpower, leading to lower throughput and longer response times as they expand to accommodate a greater number and variety of articles, eventually reaching a point of diminishing returns where further capacity gains become cost-prohibitive.
Innovation Solution
A method and system utilizing a vehicle with both horizontal and vertical drive systems to efficiently navigate and interact with a moveable track, allowing for the horizontal and vertical movement of items within a storage assembly, enabling precise positioning and transfer of items between the vehicle and storage locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the capacity of existing automation infrastructure is incrementally expanded, then throughput and functionality are improved, but cost and complexity increase to the point of diminishing returns
Solution Approach 1:
The system is divided into modular components: autonomous vehicles, movable racks, and fixed track segments. Each module can be independently added or removed, allowing capacity expansion without proportionally increasing overall system complexity. Vehicles operate independently on the track network, and racks can be individually repositioned, enabling scalable deployment.
Solution Approach 2:
The track infrastructure is made movable through the vehicle-rack interaction mechanism. Vehicles can lift and reposition racks along the track, transforming previously static storage locations into dynamic, reconfigurable positions. This dynamic capability allows the system to adapt to changing throughput requirements without building entirely new infrastructure.
2Adaptability or versatility
If the capacity of existing automation infrastructure is incrementally expanded, then functionality is improved, but cost increases to the point of diminishing returns
Solution Approach 1:
The track serves multiple functions: it acts as a guide rail for vehicle movement, a support structure for movable racks, and a transfer mechanism when vehicles lift and reposition racks. This multi-functionality reduces the need for separate specialized infrastructure for different operations, improving versatility without proportionally increasing complexity or cost.
Solution Approach 2:
Vehicles autonomously navigate the track network and independently perform rack repositioning operations by lifting and moving racks to desired locations. The system self-manages its own reconfiguration without requiring external intervention or additional complex control infrastructure, enhancing adaptability while keeping the control system manageable.
3Productivity
If resources such as space and equipment are not efficiently utilized, then throughput decreases and response times increase
Solution Approach 1:
Racks are pre-positioned along the track at strategic locations before needed, and vehicles continuously navigate the track network in readiness. When retrieval or storage operations are required, vehicles can quickly reach the appropriate locations and execute transfers, minimizing response time. The system maintains a ready state without requiring reactive reconfiguration.
Solution Approach 2:
The control system monitors vehicle positions, rack locations, and system state in real-time, dynamically dispatching vehicles to optimize throughput. This feedback mechanism ensures efficient utilization of vehicles and space, preventing idle time and ensuring that response times are minimized by directing resources to where they are most needed at any given moment.
Data Source
AI summary
A system may include a vehicle for delivering items and a moveable track that cooperates with the vehicle. The moveable track may cooperate with a storage system having storage locations for storing items. The vehicle may drive into the moveable track and lift the track using a vertical drive mechanism. The vehicle may include a horizontal drive system operable to drive the vehicle horizontally along the ground to carry the moveable track to a position adjacent the storage location. The vehicle may operate the vertical drive system to drop the moveable track adjacent the storage system. Additionally, the vehicle may operate the vertical drive to drive up the moveable track to an elevated position adjacent one of the storage locations in the storage system. The vehicle may include a transfer mechanism for transferring items between the vehicle and the storage location while the vehicle is in the elevated position.