Robotic Container Sequencing for Dense Stack Retrieval
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Solution Overview
Problem
Existing robotic storage and picking systems face challenges in efficiently combining disparate containers into coherent groups for customer orders or delivery routes, particularly in enclosed spaces where the height of robotic load handlers restricts stack height and storage density.
Innovation Solution
A sequencing system utilizing a grid pattern of tracks with robotic load handling devices that lift and deposit containers in a predetermined sequence, allowing for efficient grouping and allocation of containers on a conveyance system above the grid, enabling flexible and optimized storage and retrieval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robotic load handler with sufficient height is used to extract the highest stack of containers in a single operation, then the height of the tube must be at least as high as the height of the largest stack of containers, but this restricts the maximum height of stacks when used in an enclosed space such as a warehouse
Solution Approach 1:
The load handling function is segmented between two separate devices: a first load handling device that operates on a track system at the top of stacks for extracting containers, and a second load handling device that operates at the base of stacks for depositing containers. This segmentation allows the first device to have sufficient height for extracting from tall stacks without restricting the overall stack height in enclosed spaces, as the second device handles base-level operations.
Solution Approach 2:
A conveyance system acts as an intermediary between the first load handling device (at the top) and the second load handling device (at the base). The conveyance system receives containers from the first device and transports them to the second device, enabling the two devices to cooperate efficiently despite being separated vertically, thus resolving the contradiction between extraction capability and space constraints.
2Quantity of substance
If containers are stored in dense stacks to maximize storage density, then more containers can be stored in a given space, but existing systems lack efficient mechanisms to retrieve and sequence specific containers from these dense stacks
Solution Approach 1:
The conveyance system serves as an intermediary that bridges the storage stacks and the sequencing positions. It receives containers from the first load handling device and transports them to predetermined sequencing positions, enabling efficient retrieval and ordering of containers from dense stacks without requiring complex manual intervention or overly complicated retrieval mechanisms.
Solution Approach 2:
The system performs preliminary sequencing of containers at designated positions on the conveyance system before final delivery. Containers are arranged in predetermined sequences based on their destination or retrieval priority while being transported, which simplifies subsequent handling and maintains high storage density without proportionally increasing retrieval complexity.
3Ease of operation
If a track system forming a grid is used to allow robotic load handling devices to move around stacks, then access to containers is improved, but the system occupies horizontal space that could otherwise be used for storage
Solution Approach 1:
The system transitions from horizontal movement of load handlers to vertical operation. The first load handling device operates vertically at the top of stacks and the second operates vertically at the base, with container transfer occurring through the vertical conveyance system. This dimensional change eliminates the need for extensive horizontal track systems, freeing up floor space for additional storage while maintaining easy container access through vertical retrieval paths.
Data Source
AI summary
A sequencing system and a robotic storage and picking system include a plurality of containers disposed in stacks beneath a grid having a first set of tracks and second set of tracks, the first and second sets of tracks being disposed substantially perpendicular to each other. Plural load handling devices are operable on the grid, the load handling devices lifting and depositing containers from and to the stacks. The load handling devices can deposit containers on to conveyor belts into predetermined positions, the positions being fillable in any random order and multiple positions being fillable at any one time.