Multi-Tier Rack Conveying Layout for Faster Bin Sorting
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Solution Overview
Problem
Existing warehousing systems face issues of low storage access efficiency, insufficient space utilization, and high ground costs due to the need for large areas and dedicated sorting systems, leading to inefficient goods movement and high configuration costs.
Innovation Solution
A rack system with multiple tiers and fixed rail conveying apparatuses that allow for the use of movable members to drive task modules, enabling direct access and transfer of goods to and from freight robots, and allowing robots to operate within the warehousing space, thus optimizing space utilization and sorting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional warehousing systems use dedicated sorting systems and warehousing freight robots, then goods can be sorted and conveyed, but the area required becomes large and ground costs increase
Solution Approach 1:
The patent combines the warehousing function and sorting function into a single integrated system. The rack structure serves both as storage and as the sorting conveyor path, eliminating the need for separate dedicated sorting systems and reducing the overall area required for warehousing and sorting operations.
Solution Approach 2:
The rack is designed to perform multiple functions: it serves as both the storage structure for bins and the conveying path for goods. The same structural elements (rails, uprights, tiers) are used for both warehousing and sorting operations, making the system multi-functional and space-efficient.
2Productivity
If warehousing freight robots are used to move goods from warehouse rack to sorting table, then goods can be conveyed, but the goods in-out speed is limited by the robot's conveying capability
Solution Approach 1:
The fixed rail conveying apparatus enables continuous movement of goods along the rack structure. Multiple task modules can operate simultaneously at different positions, and the conveyor system maintains continuous flow rather than discrete robot-mediated transfers, significantly improving goods in-out speed and reducing conveying time.
3Productivity
If traditional warehousing systems are configured with dedicated sorting systems, then sorting can be performed, but the configuration costs become extremely high
Solution Approach 1:
The patent merges the sorting system with the warehousing rack structure itself. The rails, task modules, and conveying mechanisms are integrated into the rack, eliminating the need for separate dedicated sorting equipment and reducing overall system configuration complexity and cost.
Solution Approach 2:
The rack structure is designed to serve dual purposes as both storage and sorting system. The same structural components (tiers, rails, uprights) perform both warehousing and sorting functions, reducing the number of separate systems needed and lowering configuration costs.
4Quantity of substance
If multiple racks are arranged to increase storage capacity, then space utilization improves, but the area occupied increases and ground costs rise
Solution Approach 1:
The patent utilizes vertical space by arranging racks in multiple tiers stacked vertically. This three-dimensional arrangement allows multiple levels of storage within the same ground footprint, significantly increasing storage capacity without proportionally increasing the ground area occupied.
Data Source
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AI summary
A rack (10), which is used for warehousing. The rack is provided with a multi-layer storage space (101), wherein a goods box (104) is placed at each warehousing site (103) of the storage space; a fixed rail conveying apparatus (102) or fixed rail conveying apparatuses (102) is/are provided on one side and/or both sides of the rack, by means of one first moving member (13), each fixed rail conveying apparatus drives a task module (14) for storing/retrieving the goods box and/or goods, so as to place the goods into or retrieve the goods from a connecting assembly of a freight robot (17) operating at the bottom (16) of the rack, a partition plate (18) for one or more warehousing sites on the bottom-most rack tier is removed from the rack so as to provide a passage for the freight robot on the ground; alternatively, one or more rack tiers (19) are removed from the rack to provide a matching height for supporting the operation of the freight robot on the ground. The present application greatly improves the warehousing space utilization rate and goods incoming/outgoing speed and sorting efficiency of existing racks and warehousing systems.