Overhead Load Handler Layout for Dense Grid Storage Retrieval

The patent transitions from horizontal aisle-based access to vertical access by stacking containers and using overhead cranes. Containers are arranged in vertical stacks along rows, eliminating the need for horizontal aisles between rows. The crane system accesses containers from above, moving them vertically to retrieve or store products, thereby achieving both high storage density and full accessibility without requiring horizontal circulation space.

The overhead crane system serves multiple functions: it stacks containers vertically to achieve high density, retrieves containers from any position in the stack, transports containers between locations, and can handle both single containers and multiple containers simultaneously. This multi-functional approach eliminates the need for separate specialized mechanisms for each operation, reducing overall system complexity while maintaining high storage density.

The patent extracts the gripping function from a large rectangular tube structure and implements it through a compact end effector attached to the crane. The end effector uses gripper fingers or clamps that can be positioned precisely at the container location, providing the same gripping capability without the bulky tube structure. This reduces the device footprint significantly while maintaining the ability to grip and manipulate containers effectively.

The crane system employs a dynamically adjustable boom or arm mechanism that can extend and retract, raise and lower the end effector to any height within the stack. Instead of requiring a fixed tube height equal to the maximum stack height, the dynamic crane can adapt its reach and positioning to accommodate stacks of varying heights, enabling single-operation extraction from any stack while allowing the storage system height to be optimized independently of the retrieval device dimensions.