Rack Assembly Layout With Tote Transfer for Dense Warehouse Storage
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Solution Overview
Problem
Existing warehousing systems suffer from low-density storage due to inefficient use of space, necessitating a high-density intelligent storage solution.
Innovation Solution
A high-density intelligent storage system comprising rack assemblies arranged in parallel with side-by-side racks and a tote transport mechanism, facilitated by a storage and retrieval robot that delivers totes between racks, utilizing a central control module for rational storage and retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If racks are arranged with aisles between them for robot access, then robot mobility is enabled, but warehouse space utilization decreases
Solution Approach 1:
The patent combines multiple racks into rack assemblies where racks are arranged side-by-side without traditional aisles between them. The tote transport mechanism serves as a shared resource that enables access to totes on both sides of each rack, eliminating the need for separate aisles and thereby increasing warehouse space utilization while maintaining robot mobility.
Solution Approach 2:
The tote transport mechanism acts as an intermediary that enables robot access to totes stored on racks without requiring direct robot navigation through aisles. The mechanism transports totes horizontally to the robot, allowing the robot to retrieve or deposit totes from positions that would otherwise be inaccessible without consuming warehouse floor space.
2Area of stationary object
If racks are placed side-by-side without aisles, then space utilization increases, but access to totes becomes more difficult
Solution Approach 1:
The tote transport mechanism serves as an intermediary device that bridges the gap between the robot and totes stored on racks. It receives totes from the robot and transports them horizontally to the appropriate rack positions, enabling access to totes on both sides of each rack without requiring the robot to physically navigate between racks.
Solution Approach 2:
The system segments the tote access function from the rack structure itself. Instead of the robot directly accessing totes on racks through aisles, the access function is segmented into: (1) robot deposits tote on tote transport mechanism, (2) mechanism transports tote to rack, (3) mechanism places tote on rack. This segmentation enables compact rack arrangement while maintaining access capability.
3Quantity of substance
If multiple totes are stored parallel on racks, then storage density increases, but the distance between adjacent totes increases
Solution Approach 1:
The patent transitions from storing totes in a single linear dimension to utilizing two dimensions by arranging racks side-by-side in parallel. Multiple totes can be stored at different horizontal positions across multiple racks, and the tote transport mechanism enables efficient access to totes at any position along the parallel rack arrangement, effectively reducing the distance between adjacent totes by utilizing the lateral dimension.
Data Source
AI summary
The present invention discloses a high-density intelligent storage system and a storage method. The storage system includes rack assemblies and a storage and retrieval robot. A plurality of rack assemblies are provided, and the plurality of rack assemblies are arranged in parallel. The storage and retrieval robot is configured to transfer totes. An aisle is provided on at least one side of each rack assembly for allowing for movement of the storage and retrieval robot. Each rack assembly includes a pair of racks arranged side-by-side and a tote transport mechanism. The tote transport mechanism is in communication with the pair of racks to deliver totes between the two racks. The storage and retrieval robot is drivingly connected to the tote transport mechanism, and the storage and retrieval robot and the tote transport mechanism can deliver the tote to each other. With such an arrangement, the racks cooperate with the tote transport mechanism so that the layout design of the rack assemblies is rational and orderly, and the side-by-side placement of the racks can reduce the number of unnecessary aisles in a warehouse. Through the rational and orderly multi-tote parallel storage of the tote transport mechanism on the racks, the distance between adjacent totes is reduced, and the space utilisation rate of the warehouse is significantly increased.