Multi-Trolley Rail Grid for Port Congestion in Container Storage
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Solution Overview
Problem
Current automated storage and retrieval systems face congestion issues at ports due to the limited capacity of container handling vehicles, which becomes exacerbated as storage grids increase in size, leading to inefficiencies in moving storage containers.
Innovation Solution
The implementation of a multi-trolley vehicle system with a trolley assembly and motorized drive vehicles that can move on a rail system, allowing for horizontal movement and increased capacity by using transfer zones with relocatable transfer columns, reducing the need for additional ports and conveyor infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the storage grid size increases, then the storage capacity increases, but the congestion at ports worsens due to limited vehicle capacity
Solution Approach 1:
The system divides the port operations into multiple segments by introducing transfer zones with relocatable transfer columns. Instead of a single congested port, the system creates multiple access points (ports and transfer zones) that can be dynamically activated. The multi-trolley vehicle operates on a rail system that connects storage columns to these distributed access points, segmenting the throughput bottleneck into parallel channels that reduce congestion.
Solution Approach 2:
The system adds a temporal dimension to port access by implementing relocatable transfer columns that can be moved to different positions. This allows the system to dynamically reconfigure access paths and distribute traffic across multiple dimensions (different ports, different time slots), transforming a single-dimension congestion problem into a multi-dimensional flow optimization problem that increases overall throughput.
2Productivity
If additional ports and conveyor infrastructure are added, then the port capacity increases, but the system complexity and cost increase
Solution Approach 1:
The transfer columns are designed as multi-functional units that can serve multiple purposes: they act as temporary storage locations, transfer points between different rail lines, and dynamic access points for the multi-trolley vehicle. This universal design allows the system to increase capacity without adding dedicated infrastructure for each function, reducing overall complexity compared to having separate specialized components.
Solution Approach 2:
The system employs relocatable transfer columns that can be dynamically repositioned along the rail system based on operational demands. This dynamic configuration allows the infrastructure to adapt to changing storage and retrieval patterns, providing the flexibility of a complex system with the simplicity of a reconfigurable rather than permanently expanded infrastructure.
3Productivity
If conventional container handling vehicles are used, then the system structure is simple, but the capacity to move storage containers is limited
Solution Approach 1:
The system merges multiple trolley units into a single multi-trolley vehicle that can transport multiple storage containers simultaneously. Instead of using several separate conventional vehicles that would each require independent control and infrastructure, the patent combines their functions into one integrated unit that operates on the existing rail system, increasing capacity while maintaining relatively simple system architecture.
Solution Approach 2:
The multi-trolley vehicle acts as an intermediary between the storage columns and the ports/transfer zones. This intermediate vehicle design allows the system to handle multiple containers per trip without requiring direct coupling between storage and port infrastructure, providing flexibility in vehicle design while simplifying the overall system configuration.
Data Source
AI summary
An automated storage and retrieval system that includes a rail system that includes a first set of parallel tracks arranged in a horizontal plane and extending in a first direction, and a second set of parallel tracks arranged in the horizontal plane and extending in a second direction that is orthogonal to the first direction. The first and second sets of tracks form a grid pattern in the horizontal plane including a plurality of adjacent grid cells, each grid cell includes a grid opening defined by a pair of neighboring tracks of the first set of tracks and a pair of neighboring tracks of the second set of tracks; and a plurality of stacks of storage containers arranged in storage columns located beneath the rail system, where each storage column is located vertically below a grid opening.