Rack-Integrated Lifter Segments Vertical Transport in Shuttle Storage
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Solution Overview
Problem
Conventional storage and retrieval systems in warehousing face inefficiencies due to the singular use of vertical elevators and storage and retrieval devices, which limit picking performance and capacity, especially in taller or deeper racks, as they create bottlenecks in material flow and restrict the ability to operate multiple devices within the same rack aisle.
Innovation Solution
A system with multiple rack-bound vehicles and integrated lifters that allow for simultaneous operation of multiple load-handling devices across multiple rack planes, eliminating the need for a single vertical elevator bottleneck by enabling horizontal and vertical movement within the rack aisle, and allowing vehicles to cross and assist each other to balance peak loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single vertical elevator is used at the front end of the rack aisle, then the system structure is simple, but the material flow capacity is limited and creates a bottleneck
Solution Approach 1:
The single vertical elevator is segmented into multiple vertical elevators distributed at different positions along the rack aisle. Each vertical elevator serves a specific zone, eliminating the bottleneck effect of a single centralized elevator while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
The system transitions from a single-point vertical transport (one elevator at front end) to a distributed multi-point vertical transport system. Multiple vertical elevators are positioned along the longitudinal axis of the rack aisle, creating a two-dimensional transport network that increases capacity without proportionally increasing complexity.
2Quantity of substance
If the rack height is increased to store more units, then the storage capacity is improved, but the path length for the vertical elevator increases and reduces performance
Solution Approach 1:
The tall rack aisle is segmented into multiple zones, each served by its own vertical elevator. This distributes the vertical transport load across multiple parallel paths, preventing any single elevator from becoming a bottleneck despite the increased overall rack height and storage capacity.
Solution Approach 2:
The system adds the longitudinal dimension to vertical transport by positioning multiple vertical elevators at different locations along the rack aisle. This creates parallel vertical transport paths that can operate simultaneously, maintaining performance as storage capacity increases through greater rack height.
3Quantity of substance
If the rack aisle depth is increased to store more units, then the storage capacity is improved, but the path length for storage and retrieval devices increases and reduces performance
Solution Approach 1:
The deep rack aisle is segmented into multiple longitudinal zones, each with its own vertical elevator and serving area. Storage and retrieval devices operate within smaller sub-zones rather than traversing the entire aisle length, reducing travel distances and time while maintaining increased overall storage capacity through the extended aisle depth.
Solution Approach 2:
The system introduces vertical transport at multiple longitudinal positions, creating a two-dimensional access network. This allows storage and retrieval devices to serve nearby zones efficiently without crossing the entire aisle, reducing path lengths and time loss while accommodating deeper rack configurations for increased capacity.
4Productivity
If multiple storage and retrieval devices are used in the same rack aisle, then the productivity is improved, but the devices cannot overtake each other and create conflicts
Solution Approach 1:
The rack aisle is segmented into multiple independent operational zones, each with its own vertical elevator and designated storage/retrieval devices. This spatial segmentation allows multiple devices to operate simultaneously in different zones without conflicts or overtaking requirements, maintaining high productivity while simplifying coordination.
Solution Approach 2:
The system creates a two-dimensional operational matrix with multiple vertical elevators positioned along the aisle, enabling storage and retrieval devices to operate at different longitudinal positions simultaneously. This distributed architecture eliminates device conflicts by providing parallel operational paths rather than requiring single-file movement.
Data Source
AI summary
A system for storing and picking storage units including a rack arrangement having a plurality of racks, a plurality of rack-bound vehicles adapted to travel in a rack aisle for storing and retrieving the storage units into and from the storage locations in a transversal direction, wherein a rack-integrated lifter includes a load-handling device for transferring storage units between a rack-integrated handing-over location and at least one rack-integrated buffer location arranged only vertically beneath, or only vertically above, the handing-over location and at a transferring device for exchanging storage units between a feeding/discharging conveyor and the handing-over location.