Rack-and-Tray Fulfillment Layout for Space-Efficient Picking
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Solution Overview
Problem
Existing goods-storage systems face issues of poor space utilization, ergonomics, and cumbersome refilling due to the use of mobile storage pods, leading to inefficiencies in warehouse operations.
Innovation Solution
A system combining freely erectable racks with removable trays and automated depositing and retrieving machines, along with autonomous transport units, allows for flexible storage configurations and improved ergonomics by separating storage and transport functions, enabling higher racks and easier handling of articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mobile storage pods are used, then scalability and quick implementation are improved, but space utilization deteriorates
Solution Approach 1:
The system divides the storage function into two separate components: mobile storage pods and fixed infrastructure (racks and depositing/retrieving machines). This segmentation allows the mobile pods to provide scalability while the fixed infrastructure optimizes space utilization by eliminating the need for wide aisles and allowing higher rack configurations.
2Adaptability or versatility
If mobile storage pods are used, then scalability is improved, but ergonomics deteriorates
Solution Approach 1:
The system extracts the storage function from the mobile pod and places it in the fixed rack structure. The mobile pod is reduced to merely a transport vehicle that delivers articles to picking stations, eliminating the ergonomic problems of picking from elevated positions while maintaining scalability through the mobile transport capability.
3Loss of time
If mobile storage pods are used, then quick implementation is improved, but refilling process deteriorates
Solution Approach 1:
The system implements automated refilling where depositing machines automatically transfer articles from storage racks to mobile pods without manual intervention. This self-service mechanism simplifies the refilling process while maintaining the quick implementation advantage of mobile pods.
4Area of stationary object
If fixedly installed racks are used, then space utilization is improved, but adaptability deteriorates
Solution Approach 1:
The system combines fixed infrastructure with mobile dynamic elements. The fixed racks provide optimized space utilization, while the mobile storage pods provide adaptability and scalability. This hybrid approach allows the system to maintain both space efficiency and flexibility.
Data Source
AI summary
A goods-storage and order-fulfillment system having a rack store consisting of stackable rack units forming a multi-level shelving rack, with each shelf configured to store a plurality of articles, and including an automated depositing and retrieving machine that has its own travel drive and is automatically controlled and contactlessly guided for depositing trays or articles into and/or retrieving the same from the shelving racks. The system includes an automated transport unit for receiving articles from or transferring articles to the depositing and retrieving machine to transport an individual article unloaded from the tray to a picking station or to transfer an individual article to the tray or to the machine, the transport unit being floor-bound and having its own travel drive and being automatically controlled and contactlessly guided. The system includes at least one picking station supplied with individual articles by the transport unit for at least partial order fulfillment.