Pallet Storage Flow Using Gravity-Fed Inclined Lanes
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Solution Overview
Problem
Conventional storage systems face inefficiencies and logistical challenges in moving pallets from a rearward position to the front of a storage lane, requiring multiple expensive pallet transportation carts and consuming time as they are shuttled between different storage lanes.
Innovation Solution
A storage system with a first flat storage section and a second inclined flow section where pallets are moved to the front by gravity, utilizing a transition section and low friction wheels, speed controllers, and pallet separators to manage pallet flow without the need for continuous pallet cart movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated pallet transportation carts are used to move pallets from rearward position to front of storage lane, then pallet transportation is achieved, but the system requires multiple expensive carts and continuous movement between lanes which consumes time and increases operational complexity
Solution Approach 1:
The storage lane is divided into two distinct sections: a flat storage section for stationary pallet storage and an inclined flow section for automated pallet movement. This segmentation allows different operational modes in different zones, eliminating the need for continuous cart shuttling between lanes while maintaining high productivity.
Solution Approach 2:
The patent introduces an inclined plane dimension to the storage system, creating a gravity-driven flow section that allows pallets to move automatically from rear to front. This dimensional change transforms the traditional horizontal cart-based transport into a vertical gravity-based flow, reducing the number of carts needed.
2Adaptability or versatility
If pallet transportation carts are shuttled between different storage lanes, then pallets can be transported to multiple lanes, but workflow must stop as carts are moved which consumes time
Solution Approach 1:
The inclined flow section enables pallets to move themselves automatically under gravity from the storage section to the front of the lane. This self-service mechanism eliminates the need for external cart intervention during normal pallet flow operations, allowing continuous workflow without interruptions for cart repositioning.
Solution Approach 2:
Pallets are positioned on the inclined flow section in advance, where they automatically flow forward under gravity before being needed at the front. This preliminary positioning and automatic flow eliminates the need for last-minute cart intervention, ensuring continuous workflow and reducing time loss.
3Quantity of substance
If the storage area density is increased with limited sight lines and access, then storage capacity is improved, but it becomes time consuming and logistically problematic to move pallets from rearward position to front
Solution Approach 1:
By introducing the inclined plane dimension, the system enables automatic pallet flow in high-density storage configurations. The gravity-driven flow mechanism works effectively in deep storage lanes with limited access, eliminating the time-consuming manual or cart-based repositioning operations that would otherwise be required in such dense configurations.
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
Reduces the need for pallet cart movement between lanes, enhancing efficiency and reducing operational time by allowing pallets to flow forward one at a time, thus minimizing the requirement for multiple carts and optimizing workflow.
Implementation Method 1
a second inclined flow section where pallets are moved to the front of the storage bay lane by the force of gravity
Implementation Method 2
The inclined flow section includes a low friction surface, such as a plurality of wheels protruding through the support rails
Data Source
AI summary
A storage system and method wherein a storage rack has a first flat section, where pallets are loaded onto storage rails by an automated pallet transportation cart, and a second inclined flow section, where pallets are moved to the front of the storage lane by the force of gravity. A transition section can be positioned between the flat section and the inclined section. The transition section has rails and spacing for a pallet cart to load pallets onto the inclined section. As the front pallet is removed, the second pallet (and subsequent pallets on the inclined section) travels forward to take its place under the force of gravity. Therefore, no pallet cart is needed to unload the inclined section.