Non-orthogonal Pallet Flow Racking for Dense Storage
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Solution Overview
Problem
Conventional pallet storage systems face inefficiencies due to fixed rectangular layouts, leading to underutilization of storage space and increased travel distances for material handling, which hampers productivity and scalability in response to changing inventory demands.
Innovation Solution
The implementation of dense pallet storage systems with non-orthogonal and non-rectangular arrangements of pallet flow racks, allowing for a variety of lane lengths and non-parallel/orthogonal aisles, enabling flexible storage configurations that match SKU inventory requirements and reduce travel distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional rectangular pallet storage systems are used, then structural simplicity and ease of implementation are maintained, but storage space utilization is underoptimized and travel distances for material handling increase
Solution Approach 1:
The patent applies asymmetry by replacing conventional rectangular racking arrangements with non-rectangular configurations (triangular, trapezoidal, hexagonal, or irregular shapes). This asymmetric layout optimizes space utilization by better fitting warehouse footprints and reducing wasted corner spaces, while also shortening travel distances for material handling operations.
Solution Approach 2:
The patent transitions from traditional two-dimensional rectangular grid layouts to multi-dimensional geometric arrangements. By incorporating triangular, trapezoidal, and other polygonal configurations, the system adds geometric complexity that enables more efficient three-dimensional space utilization and creates multiple access paths for material handling.
2Adaptability or versatility
If fixed rectangular layouts are used, then system simplicity is maintained, but adaptability to changing inventory demands and SKU proliferation is reduced
Solution Approach 1:
The patent segments the warehouse storage system into multiple independent geometric zones (triangular sections, trapezoidal sections, hexagonal sections) that can be independently configured and reconfigured. Each zone can be optimized for specific inventory types or order priorities, allowing flexible adaptation to changing SKU profiles and demand patterns without requiring complete system redesign.
Solution Approach 2:
The patent implements dynamic adaptability by designing racking systems with variable lane lengths and adjustable geometric configurations. The non-rectangular layouts allow for easy reconfiguration of aisle widths, lane lengths, and zone boundaries to respond to seasonal inventory changes, new product introductions, and shifting order fulfillment requirements.
3Productivity
If uniform lane lengths are used in rectangular systems, then manufacturing and installation simplicity is maintained, but efficiency in matching diverse SKU storage requirements is reduced
Solution Approach 1:
The patent applies local quality by creating zones with different geometric characteristics tailored to specific inventory requirements. Triangular zones may accommodate high-velocity SKUs with shorter lanes for quick access, while trapezoidal or hexagonal zones can accommodate bulk storage needs with longer lanes. Each local zone is optimized for its specific function, improving overall order fulfillment efficiency.
Solution Approach 2:
The patent utilizes parameter changes by varying lane lengths, aisle widths, and zone geometries across different sections of the warehouse. This allows optimization of storage density and access efficiency for different product categories simultaneously, with parameters such as lane length and rack height adjusted locally to match specific SKU characteristics and order frequency patterns.
4Length of moving object
If orthogonal aisles are used, then navigation simplicity is maintained, but travel distances for material handling increase
Solution Approach 1:
The patent introduces curved and angled aisle configurations replacing strict orthogonal layouts. Triangular and hexagonal zone arrangements create diagonal and angled access paths that shorten the distance between storage locations and picking areas. The curved geometries of non-rectangular zones enable more direct routing for material handlers, reducing unnecessary travel distance while maintaining navigability.
Data Source
AI summary
Systems and methods for enhancing efficiencies of dense pallet storage systems are described. For example, this document describes systems and methods for enhancing efficiencies of dense pallet storage systems by arranging pallet flow racking to define a high variety of lane lengths and non-orthogonal aisles.