Multi-Temperature ASRS Layout With Zoned Shuttles and External Lift
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Solution Overview
Problem
Space and resource inefficiencies in order fulfillment centers due to the need for separate automated storage and retrieval systems for multiple temperature zones, particularly exacerbated by the low demand for frozen products which require specialized climate-controlled environments.
Innovation Solution
A modular automated storage and retrieval system that combines storage for multiple temperature zones, such as chilled and frozen, using a thermally insulated enclosure with shuttles limited to specific temperature zones to prevent frost and condensation issues, and a lift system that operates between zones through an air barrier, allowing for efficient storage and retrieval of items across temperature zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate automated storage and retrieval systems are created for each temperature zone, then temperature control reliability is improved, but space utilization and capital efficiency deteriorate
Solution Approach 1:
The patent combines multiple temperature zones (frozen, chilled, ambient) into a single automated storage and retrieval system. The rack structure contains shelves spanning across temperature zone boundaries, and shuttles operate continuously through multiple zones without exiting the system. This merging approach maintains temperature control reliability while significantly improving space utilization compared to separate systems for each zone.
Solution Approach 2:
The automated storage system is designed with universal components that serve multiple temperature zones. The shuttles are capable of operating in different temperature environments, the rack structure supports storage across multiple zones, and the control system manages operations throughout the entire multi-temperature system. This multi-functionality reduces capital requirements and improves overall space efficiency.
2Adaptability or versatility
If shuttles operate between different temperature zones, then system versatility is improved, but frost and condensation problems increase
Solution Approach 1:
The patent introduces air curtains as intermediary elements at the boundaries between temperature zones. These air curtains create air barriers that prevent direct thermal exchange and condensation between zones while still allowing shuttles to pass through. This enables shuttles to operate versatily across multiple temperature zones without suffering from frost and condensation problems.
3Temperature
If a thermally insulated enclosure is used to define low temperature zones, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the storage system into distinct temperature zones (frozen, chilled, ambient) within a single rack structure. Each zone is defined by thermally insulated enclosures that can be independently controlled. This segmentation allows precise temperature control for each zone while using a unified rack and shuttle system, thereby managing device complexity through modular organization.
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
This solution enables efficient storage and retrieval of chilled and frozen products in a compact space without separate racks or aisles, reducing capital and operational costs while maintaining temperature control, and allows for flexible adjustments based on changing product demand.
Implementation Method 1
a refrigeration system to lower the temperature in said low temperature zone
Implementation Method 2
a thermally insulated enclosure enclosing some of said levels of said rack to define a low temperature zone
Implementation Method 3
A moveable air barrier may be provide between the lift and thermally insulated enclosure
Data Source
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AI summary
A multiple temperature automated storage system includes a rack with multiple levels of shelves defining item storage positons, an aisle at each level, and a plurality of shuttles to operate in the aisles for storing items to and retrieving items from the storage positons. A thermally insulated enclosure encloses some levels of the rack to define a low temperature zone with the remaining levels of the rack defining a higher temperature zone. A method of storing items at two different temperatures in a common automated storage system includes having a first portion of the automated storage system enclosed in a thermally insulated enclosure and a second portion of the automated storage system outside of the thermally insulated enclosure. A lift is provided in the second portion for supplying items to and retrieving items from both of the first and second portions, without entering the first portion.