Relay Module Conveyors for Automated Storage Port Congestion
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Solution Overview
Problem
Automated storage and retrieval systems face congestion issues around pick-up and drop-off ports due to container handling vehicles moving without payload, leading to inefficiency and space utilization challenges.
Innovation Solution
The introduction of a relay module below a port column, comprising a port station, first and second conveyors, and a lateral displacement device, allowing for the relay of storage containers between the port column and an access station, reducing congestion by enabling continuous transport and buffering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate pick-up and drop-off ports are used, then container handling vehicles can perform dedicated functions, but system complexity and space requirements increase
Solution Approach 1:
The patent combines pick-up and drop-off ports into a single integrated port structure. Container handling vehicles can perform both pick-up and drop-off operations at the same port location, eliminating the need for separate dedicated ports and reducing overall system complexity while maintaining operational efficiency
Solution Approach 2:
The integrated port is designed to serve multiple functions - both pick-up and drop-off operations occur at the same location. This multi-functional design allows the port to handle different container flows without requiring separate specialized structures, thereby reducing complexity while preserving operational capabilities
2Ease of operation
If container handling vehicles move without payload between ports, then container retrieval is enabled, but congestion and inefficiency increase
Solution Approach 1:
The patent implements continuous conveyor systems that maintain constant container flow between storage columns and the integrated port. This eliminates idle periods where vehicles would otherwise travel empty, ensuring continuous useful action and improving operational efficiency by keeping the system constantly productive
Solution Approach 2:
Conveyors act as intermediary transport mechanisms between storage columns and the port, handling container movement independently from the vehicles. This allows vehicles to focus on retrieval operations while conveyors manage the continuous flow, reducing congestion and improving overall efficiency
3Productivity
If multiple separate ports are provided, then congestion is reduced, but space utilization and system complexity increase
Solution Approach 1:
The patent merges multiple separate ports into a single integrated port structure that handles both pick-up and drop-off operations. This consolidation reduces the total space required for port infrastructure while maintaining congestion reduction benefits through optimized internal container flow management
Solution Approach 2:
The integrated port utilizes vertical dimension with multiple levels for different operations. Storage containers are stacked vertically and accessed through the same port footprint, effectively increasing capacity without proportionally increasing horizontal space requirements
Data Source
AI summary
An automated storage and retrieval system includes at least one relay module for relaying storage containers between a port column and an access station. The relay module is arranged below a port column. The relay module includes a port station, a first conveyor, a second conveyor, each arranged at a side of the port station, and a lateral displacement device. The port station receives storage containers dropped off from and to be picked up through the port column. The first conveyor is adapted to transport storage containers to an access station. The second conveyor is adapted for transporting storage containers from the access station. The lateral displacement device is arranged to transport storage containers between the port station and the first conveyor, and between the second conveyor and the port station.