Opportunistic Rail Charging for ASRS Mobile Robots
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Solution Overview
Problem
Conventional automated storage and retrieval systems face inefficiencies in charging mobile robots, as they require discrete charging stations that divert robots from tasks, increase system complexity, and incur high costs due to the need for multiple chargers and power supplies.
Innovation Solution
An opportunistic battery charging system where charge rails are integrated into the track system, allowing mobile robots to recharge during normal operations using high voltage from the facility power source, with onboard chargers converting the voltage for each robot's energy storage device, enabling simultaneous and controlled rapid charging of multiple robots from a single rail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete charging stations are used for mobile robots, then robots can be recharged, but robots are diverted from order fulfillment tasks and system complexity increases
Solution Approach 1:
The charge rail enables continuous charging of mobile robots during their normal travel and operation within the storage structure. Robots charge opportunistically while moving between storage locations, eliminating the need to divert robots to discrete charging stations and maintaining continuous order fulfillment operations.
Solution Approach 2:
The charge rail serves multiple functions: it provides power for charging robots, acts as part of the track system infrastructure, and enables simultaneous charging of multiple robots. This multi-functionality reduces the need for separate dedicated charging infrastructure and minimizes system complexity.
2Reliability
If multiple discrete charging stations are deployed throughout the structure, then robot recharging is enabled, but fixed installation costs and system complexity increase
Solution Approach 1:
The charging infrastructure is merged with the existing track system by integrating charge rails into the vertical towers and horizontal rails. This consolidation eliminates the need for separate discrete charging stations and reduces overall system complexity while maintaining robot recharging capability.
Solution Approach 2:
The track system components (vertical towers and horizontal rails) serve dual purposes: providing structural support and guidance for robots, and delivering electrical power through integrated charge rails. This multi-functionality reduces the number of separate components needed in the system.
3Reliability
If conventional charge rails with DC power supplies are used, then robots can be recharged during operations, but fixed installation costs and system complexity increase due to multiple chargers required
Solution Approach 1:
The DC power supply and charger components are extracted from the fixed infrastructure and relocated to individual mobile robots. Each robot carries its own charger that connects to the charge rail during operation, eliminating the need for multiple fixed power supplies and chargers throughout the structure.
Solution Approach 2:
Each mobile robot is equipped with its own charger that autonomously connects to the charge rail during normal operations to recharge its battery. This self-service approach eliminates the need for centralized power management infrastructure and reduces system complexity.
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
This solution minimizes fixed installation costs, enhances system reliability, and allows for efficient, simultaneous charging of multiple robots, reducing downtime and operational complexity while maintaining high power capability and scalability.
Implementation Method 1
the charger on each of the plurality of mobile robots converting the first voltage from the charge rail to a second voltage smaller than the first voltage
Implementation Method 2
a plurality of rechargeable energy storage devices comprising a rechargeable energy storage device on each of the plurality of mobile robots, the rechargeable energy storage device on each of the plurality of mobile robots being charged by the second voltage
Data Source
AI summary
An opportunistic rail charging system is disclosed for recharging power supplies on mobile robots transporting goods within an automated order fulfillment system. Individual chargers may be incorporated into each mobile robot for converting a facility line voltage from the charge rail to a voltage for which the rechargeable power supplies on each mobile robot are rated.