Relay Module Buffering to Reduce Port Congestion in Storage Systems
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Solution Overview
Problem
Existing 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, conveyors, and a lateral displacement device to relay storage containers between the port column and an access station, allowing for continuous transportation and buffering to reduce congestion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If container handling vehicles move to pick-up and drop-off ports, then storage containers can be retrieved and deposited, but congestion occurs around ports due to vehicles moving without payload
Solution Approach 1:
A relay module is introduced as an intermediary component between the port column and the access station. This relay module includes a relay conveyor that receives storage containers from the port column and transports them to the access station, thereby mediating the transfer process and preventing congestion at the port area by providing an intermediate handling point.
Solution Approach 2:
The transportation function is segmented into multiple stages: the port column handles vertical deposition/retrieval, the relay module handles horizontal transfer via relay conveyor, and the access station handles final delivery/pickup. This segmentation distributes the workload and prevents congestion by dividing the previously concentrated port operations into distributed functions across multiple components.
2Duration of action of moving object
If container handling vehicles travel to retrieve containers after depositing, then continuous operation is possible, but space utilization is reduced due to empty travel
Solution Approach 1:
The relay module enables continuous useful action by maintaining a constant flow of storage containers through the relay conveyor. Containers are continuously received from the port column and transported to the access station, eliminating idle travel time for container handling vehicles and ensuring that the transportation system operates continuously with maximum space utilization.
Data Source
AI summary
A method for operating an automated storage and retrieval system includes transporting a storage container between a storage column of the automated storage and retrieval system and a relay module of the automated storage and retrieval system and utilizing a displacement device of the relay module, transporting the storage container between a port station of the relay module and a conveyor of the relay module. The automated storage and retrieval system includes a plurality of storage columns, a container handling vehicle for moving storage containers stacked in stacks of storage containers, and at least one relay module for relaying a storage container of the stack of storage containers. A relay module includes a port station for receiving storage containers, a conveyor adapted to transport storage containers between the relay module and an access station, and a displacement device for transporting the storage containers between the port station and the conveyor.