Overhead Load Handler Layout for Aisle-Free Container Retrieval
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Solution Overview
Problem
Existing storage systems face inefficiencies in storage density and accessibility, particularly in handling multiple product lines, as they require significant space for aisles and are not well-suited for selecting single containers from multi-product stacks, making them impractical for online retail and high-volume operations.
Innovation Solution
A load handling device with a compact design that moves laterally on a grid-patterned rail system, capable of lifting multiple containers into a container-receiving space, allowing for efficient retrieval and movement of containers from stacked positions without the need for extensive aisle space, and featuring a self-propelled robot vehicle with winch or crane mechanisms for efficient container handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are stacked in rows with aisles for access, then product accessibility is improved, but storage density deteriorates
Solution Approach 1:
The system transitions from two-dimensional aisle-based access to three-dimensional vertical stacking with overhead robotic access. Containers are stacked vertically to maximize space utilization, while the robotic load handler operates from above to provide access without requiring horizontal aisle space, thus resolving the contradiction between accessibility and storage density.
2Adaptability or versatility
If a rectangular tube load handler is used to grip containers at any level, then container retrieval flexibility is improved, but device height and complexity increase
Solution Approach 1:
The load handler is divided into separate functional modules: a base unit for lateral movement on rails, and detachable gripper mechanisms that can be positioned at different heights. This segmentation allows the system to achieve flexible container retrieval at any stack level without requiring a single complex structure to span the entire stack height, thereby reducing overall device complexity while maintaining versatility.
3Productivity
If the load handler tube height matches the largest stack height, then single-operation extraction is improved, but maximum stack height is restricted
Solution Approach 1:
The load handler employs dynamically adjustable gripper positions that can move vertically along the stack rather than requiring a fixed tube height matching the maximum stack. This dynamic positioning capability allows the system to efficiently retrieve containers from any height without being constrained by the maximum stack height, enabling both high productivity and increased storage capacity.
4Device complexity
If single-product stacks are used to simplify handling, then handling complexity is reduced, but floor area requirement increases
Solution Approach 1:
The robotic load handler is designed with universal capabilities to handle multi-product stacks, equipped with sensors and control systems that can identify and retrieve specific containers based on product type and location. This multi-functional design eliminates the need for separate single-product stacks, allowing diverse products to be stored in the same vertical space without increasing floor area, while the system manages the increased handling complexity through automation.
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 enhances storage system efficiency by allowing more containers to be lifted in a single operation, reducing the footprint of the load handling device, and enabling faster retrieval and movement of containers, thus improving storage density and operational speed.
Implementation Method 1
A load handling device with a compact design that moves laterally on a grid-patterned rail system, capable of lifting multiple containers into a container-receiving space
Data Source
AI summary
A load handling device is disclosed for retrieving, transporting, and delivering containers in a storage system having a grid structure formed of two substantially perpendicular sets of rails or tracks located above stacks of containers. An exemplary load handling device can include a wheel assembly, a container receiving space, and a plurality of vehicle modules. The wheel assembly can include a first set of wheels to guide movement of the load handing device in a first direction and a second set of wheels to guide movement of the load handing device in a second direction. Each of the vehicle modules can include a container lifting means arranged to lift a container into the container receiving space and each of the vehicle modules can be moveable to adjust the spacing of the containers in the load handling device.