Multi-directional Shuttle with Segmented Wheel Treads
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Solution Overview
Problem
Existing two-directional shuttle systems for automated warehouses require strict alignment tolerances between aisle and storage tracks, leading to increased costs and complexity, and are limited to single system usage per level due to the need for dual shuttles and high power consumption.
Innovation Solution
A multi-directional shuttle system with four wheel treads per side that decouples the aisle and storage tracks at a track crossing, allowing smooth transition and operation with relaxed alignment requirements, using a discontinuity between the tracks and configuring wheel treads to engage and disengage continuously, thereby supporting weight distribution and accommodating misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strict alignment tolerances are applied between aisle and storage tracks, then the shuttle can transition smoothly between tracks, but the structural cost and complexity increase significantly
Solution Approach 1:
The wheel assembly is segmented into multiple wheel treads (first, second, third, fourth treads) arranged in a specific pattern. This segmentation allows different treads to engage with different track sections during the transition, distributing the transition process across multiple contact points and reducing the alignment tolerance requirements for each individual contact point.
Solution Approach 2:
The wheel treads are arranged in a two-dimensional pattern rather than a simple linear arrangement. This dimensional arrangement allows the wheels to engage with the track in a staggered sequence, creating a progressive transition path that reduces the strictness of alignment requirements between the aisle and storage tracks.
2Adaptability or versatility
If dual shuttle systems are used to achieve two-directional movement, then movement flexibility is improved, but system cost and complexity increase due to requiring two separate shuttles with their own batteries and motors
Solution Approach 1:
A single shuttle is designed with universal functionality to perform both aisle track movement and storage track access. The shuttle comprises wheel treads configured to engage with both aisle tracks and storage tracks, eliminating the need for separate shuttles for different track types while maintaining two-directional movement capability.
Solution Approach 2:
The shuttle employs a dynamic wheel configuration where different wheel treads are engaged at different stages of the transition between aisle and storage tracks. This dynamic engagement pattern allows one shuttle to adapt its contact points with the tracks during movement, enabling flexible two-directional operation without requiring multiple shuttles.
3Device complexity
If a single shuttle with two sets of wheels is used, then device complexity is reduced, but strict tolerances on track alignment are required which increases structural cost
Solution Approach 1:
The wheel assembly is divided into multiple segmented treads that engage with the track in a sequential manner during transition. This segmentation allows the single shuttle to accommodate greater alignment variations by distributing the transition load across multiple contact points rather than requiring precise alignment at a single point.
Solution Approach 2:
The wheel tread configuration changes parameters of the transition process by introducing multiple engagement points and a staggered engagement sequence. This parameter change in the transition mechanism allows the system to function with relaxed alignment tolerances while maintaining smooth operation.
4Manufacturing precision
If discontinuity is introduced between aisle and storage tracks, then alignment tolerance requirements are relaxed, but the shuttle mechanism must be more complex to bridge the gap
Solution Approach 1:
The wheel assembly uses segmented treads that progressively engage with the storage track while disengaging from the aisle track. This segmentation allows the shuttle to bridge the discontinuity through a multi-stage transition process, where each tread engages at a different point, effectively spanning the gap created by the track discontinuity.
Solution Approach 2:
The multiple wheel treads act as intermediaries between the discontinuous aisle and storage tracks. Rather than requiring direct continuous contact between tracks, the wheel treads serve as mediating elements that transfer the shuttle from one track to the other across the discontinuity, enabling operation with relaxed alignment tolerances.
Data Source
Figure 1A~1E
Figure 2A~2D
Figure 3A~3D
AI summary
Warehouse storage system comprising a storage track (110, 210, 310, 410, 510, 610), an aisle track (106, 206, 306) comprising a track crossing (105, 205, 305, 405, 505, 605) for accessing this storage track (110, 210, 310, 410, 510, 610) and a multi-directional load carrying shuttle (130, 230, 330, 730, 830) adapted to ride on both the storage track (110, 210, 310, 410, 510, 610) and the aisle track (106, 206, 306). The aisle track (106, 206, 306) is decoupled from the storage track (110, 210, 310, 410, 510, 610) by a discontinuity between the track crossing (105, 205, 305, 405, 505, 605) and the storage track (110, 210, 310, 410, 510, 610). The shuttle (130, 230, 330, 730, 830) comprises at least four wheel treads per side for driving this shuttle (130, 230, 330, 730, 830) along a direction of the storage track (110, 210, 310, 410, 510, 610).