Robotic Container Delivery Layout for ASRS Port Congestion
Find Innovative SolutionsGenerate Solutions
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, particularly in systems where conveyor infrastructure is costly and space-constrained.
Innovation Solution
An automated storage and retrieval system incorporating a remotely operated delivery vehicle and robotic operators to transport storage containers between the grid and a second location for handling, reducing the need for multiple ports and optimizing space usage by integrating a delivery rail system that minimizes its footprint within the storage grid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If container handling vehicles frequently move between storage columns and delivery ports, then storage containers can be delivered efficiently, but congestion occurs around delivery ports due to vehicles moving without payload
Solution Approach 1:
The system separates the delivery function from the storage retrieval function by introducing a dedicated delivery vehicle that operates independently on a separate delivery rail system. This segmentation allows container handling vehicles to focus on storage operations while the delivery vehicle handles port deliveries, eliminating congestion around delivery ports.
Solution Approach 2:
A remotely operated delivery vehicle acts as an intermediary between the automated storage grid and the second location. This delivery vehicle transports storage containers along a dedicated delivery rail system, serving as a mediator that eliminates the need for container handling vehicles to repeatedly travel to delivery ports, thus reducing congestion.
2Productivity
If multiple delivery ports are added to increase availability, then more containers can be delivered simultaneously, but the system becomes more complex and requires more space
Solution Approach 1:
The delivery vehicle is designed with universal functionality to service multiple storage columns along its route. Instead of having dedicated ports for each column, a single delivery vehicle can deliver containers to any column along its path, making the system more flexible and reducing the need for multiple specialized delivery ports.
Solution Approach 2:
The delivery rail system is arranged in a linear configuration that spans multiple storage columns, transforming the traditional point-to-point port architecture into a continuous linear delivery path. This dimensional change allows a single delivery vehicle to access multiple columns without requiring multiple separate delivery ports.
3Productivity
If a robotic operator is positioned at a single delivery port, then items can be handled efficiently at that location, but the system creates a single-point failure risk
Solution Approach 1:
Multiple robotic operators are positioned at different locations along the delivery rail system, each responsible for specific zones. This creates local expertise and redundancy, where if one robotic operator fails, others can continue handling items at their respective locations, eliminating the single-point failure risk.
Solution Approach 2:
Storage containers are delivered to multiple locations along the delivery rail system in advance, and robotic operators at different locations are prepared to handle items. This preliminary distribution of delivery locations ensures that item handling can continue even if one robotic operator or location becomes unavailable.
4Adaptability or versatility
If the delivery rail system extends throughout the storage grid, then delivery vehicles can access all storage columns, but the system occupies significant space within the grid
Solution Approach 1:
The delivery rail system is designed as a dynamic, selectively activatable infrastructure. Rather than being permanently installed throughout the entire storage grid, the rail system can be deployed or activated only in specific zones where delivery is needed, allowing the system to adapt to varying delivery requirements while minimizing space occupation.
Solution Approach 2:
The delivery rail system is nested within the existing storage grid structure, utilizing the vertical and horizontal spaces already defined by the storage columns and framework. This nesting approach allows the delivery rail to occupy minimal additional space while still providing access to all storage columns.
Data Source
AI summary
The invention relates to an automated storage and retrieval system comprising an automated storage and retrieval grid and a delivery system wherein the automated storage and retrieval grid comprises a container handling vehicle rail system for guiding a plurality of container handling vehicles, the container handling vehicle rail system comprising a first set of parallel rails arranged in a horizontal plane and extending in a first direction, and a second set of parallel rails arranged in the horizontal plane and extending in a second direction which is orthogonal to the first direction, which first and second sets of rails form a grid pattern in the horizontal plane comprising a plurality of adjacent container handling vehicle grid cells, each container handling vehicle grid cell comprising a container handling vehicle grid opening defined by a pair of neighboring rails of the first set of rails and a pair of neighboring rails of the second set of rails, the container handling vehicles being operable to retrieve a storage container from a stack of storage containers beneath the container handling rail system; and a delivery column adapted for transport of a storage container between a container handling vehicle and a delivery port situated at a lower end of the delivery column; and wherein the delivery system comprises a remotely operated delivery vehicle comprising a container carrier adapted to support the storage container, the delivery vehicle being further adapted to transport the storage container between a first location represented by the delivery port and a second location, wherein the second location comprises a robotic operator for handling of product item in the storage container. The invention further relates to methods of moving storage containers with product items from storage grid and to a robotic operator at the second location for handling of product item in the storage container.