3D Multi-Rack Storage Layout for Collision-Safe Payload Transfer
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Solution Overview
Problem
Existing warehouse storage systems face challenges in efficiently managing payload storage, transfer, and retrieval, particularly in multi-rack environments, leading to issues such as collision risks, misalignment of payloads, and suboptimal storage density.
Innovation Solution
A system comprising a cell frame structure with a 3D grid of cells, robots, and a motion planner that enables vertical and horizontal traversal, using cell trays to support payloads and facilitate precise positioning for easy access by material handling equipment, along with validation and alignment mechanisms to ensure safe and dense storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional warehouse storage systems are used, then simple structure is maintained, but storage density and payload transferability deteriorate
Solution Approach 1:
The patent implements a three-dimensional rack structure with multiple levels (first level, second level, third level) and multiple racks (first rack, second rack, third rack) arranged in space. This vertical and spatial dimensionality transformation dramatically increases storage density compared to traditional flat warehouse layouts, allowing payloads to be stored at different heights and positions throughout the three-dimensional space.
Solution Approach 2:
The storage system is divided into discrete cells within each rack level, with each cell capable of holding a payload. The system segments the warehouse into multiple independent storage units that can be individually accessed and managed, enabling high-density storage while maintaining organizational structure and accessibility.
2Reliability
If manual payload handling is used, then device complexity is reduced, but collision risks and misalignment increase
Solution Approach 1:
The patent introduces a robotic arm as an intermediary device between the control system and the payloads. The robotic arm executes precise movements to transfer payloads between different rack levels and positions, eliminating direct human handling and reducing collision risks through programmable, controlled motion paths and speed regulation.
Solution Approach 2:
The system incorporates sensors and control mechanisms that monitor the robotic arm's position and movement in real-time. This feedback loop ensures precise positioning of payloads, prevents misalignment by detecting position deviations, and regulates the robotic arm's speed to avoid collisions, thereby improving transfer reliability.
3Quantity of substance
If high storage density is achieved through multi-rack systems, then storage capacity improves, but collision risks between robots increase
Solution Approach 1:
The robotic arm's speed is dynamically regulated based on its position and the positions of other robots in the multi-rack system. The control system adjusts movement speeds in real-time to maintain safe distances between robots, preventing collisions while still achieving high storage capacity through efficient space utilization.
Solution Approach 2:
Real-time feedback from sensors monitors the positions of multiple robots operating in the dense multi-rack environment. This feedback enables the control system to coordinate robot movements, regulate speeds, and prevent collisions by detecting potential conflict situations and adjusting operational parameters accordingly.
Data Source
AI summary
The system can include: a cell frame structure; a robot; and a motion planner. The system can optionally include a set of cell trays and a warehouse management system. The cell frame structure can include and/or define a set of payload storage cells; a set of transfer cells; a set of cell tray storage cells. However, the system can additionally or alternatively include any other suitable set of components. The system functions to automatically manage the storage of payloads within a grid-based structural system.