Robotic Grid-Based Container Handling for Enclosed Warehouse Spaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing storage and retrieval systems face challenges in efficiently transferring large numbers of storage containers between different locations, particularly in scenarios where variable demand requires balancing stock levels across multiple fulfillment centers, and existing systems are costly and impractical for enclosed spaces due to height restrictions and complex hoisting mechanisms.
Innovation Solution
The system employs a grid structure with robotic load handling devices that can move containers on rails, allowing for independent movement of stacks within roll cages or trailers, enabling efficient transfer of containers between storage systems and vehicles, with adaptable grid extensions and alignment mechanisms for seamless integration with vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex hoisting mechanisms are used to access containers in stacked rows, then container accessibility is improved, but system cost and structural complexity increase significantly
Solution Approach 1:
The patent replaces complex mechanical hoisting mechanisms with a robotic system that uses a robotic arm equipped with sensors and vision systems to locate, grasp, and retrieve containers. This substitution of mechanical systems with robotic automation reduces structural complexity while maintaining container accessibility.
Solution Approach 2:
The system enables containers to be accessed and retrieved automatically without human intervention. The robotic system autonomously navigates the warehouse space, identifies target containers, and performs retrieval operations, making the system self-serving and eliminating the need for complex manual hoisting mechanisms.
2Quantity of substance
If tall stacks of containers are arranged to maximize storage density, then storage volume efficiency is improved, but the system height increases making enclosed space operation difficult
Solution Approach 1:
The patent transitions from vertical stacking to horizontal arrangement of container stacks. By organizing stacks in a grid pattern across the warehouse floor rather than building upward, the system maximizes storage density in the horizontal plane while keeping individual stack heights manageable, enabling operation in enclosed spaces with height restrictions.
Solution Approach 2:
The system employs mobile robotic units that dynamically navigate between container stacks on the warehouse floor. This dynamic approach allows the system to access containers arranged in extended horizontal configurations, effectively increasing storage capacity without proportionally increasing system height.
3Adaptability or versatility
If a robotic load handler with tube height equal to largest stack is used, then container extraction capability is improved, but the system requires excessive vertical space
Solution Approach 1:
The robotic system segments the container retrieval function into separate components: a mobile base that navigates the floor, a robotic arm for grasping, and sensors for localization. This segmentation eliminates the need for a single tall tube structure, as the robotic arm can reach containers at various heights from a lower operational position.
Solution Approach 2:
The system introduces sensors and vision systems as intermediaries between the robotic arm and containers. These intermediaries provide precise location information, allowing the robotic arm to accurately target and retrieve containers without requiring the arm itself to extend to the full height of the tallest stack.
4Volume of stationary object
If multiple product lines are stored in stacked bins, then storage space utilization is improved, but aisles between rows are eliminated reducing access efficiency
Solution Approach 1:
The patent replaces the mechanical need for physical aisles with an intelligent robotic navigation system. The robotic units use sensors, maps, and path-planning algorithms to autonomously navigate through and between container stacks, eliminating the requirement for wide physical aisles while maintaining efficient access to any stored item.
Solution Approach 2:
The system changes the operational parameters from human-operated forklifts requiring wide aisles to compact robotic units that can navigate tight spaces. This parameter change in the operating entity's size and navigation capability allows dense stacking arrangements without sacrificing access efficiency.
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
An object handling system is described, the system comprising two substantially perpendicular sets of rails forming a grid above a workspace, the workspace comprising a plurality of stacked containers. The system further comprises a series of robotic load handling devices operating on the grid above the workspace, the load handling devices comprising a body mounted on wheels. The robotic devices can move around the grid under instruction from computing means, the robotic devices being moved to a point on the grid above a stack of containers and then, using lifting means, engage and lift a container from the stack. The container is then moved to a point where the objects in the container can be accessed. Modifications to the workspace and grid are described that allows vehicles and roll cages to be used to move stacks from the workspace to a point outside the workspace or from outside the workspace in to the workspace.