Robotic Grid Service Unit for Remote Load Handler Maintenance
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Solution Overview
Problem
Existing storage and retrieval systems for multiple product lines require manual intervention to repair or clean robotic load handling devices and grid surfaces, leading to increased downtime and safety risks due to the need to stop all devices for maintenance, especially in large and complex systems.
Innovation Solution
A robotic service device with latching mechanisms, camera systems, cleaning tools, and traction measurement capabilities is integrated into the frame structure to remotely diagnose, clean, and maintain robotic load handling devices, allowing for the removal and servicing of malfunctioning units without halting the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to repair or clean robotic load handling devices and grid surfaces, then maintenance can be performed, but system downtime increases and safety risks arise due to the need to stop all devices
Solution Approach 1:
The robotic service device performs maintenance tasks autonomously without requiring manual intervention. It navigates the grid independently, identifies malfunctioning load handling devices, and executes cleaning or repair operations, enabling the system to service itself and eliminate the need to halt operations for maintenance.
Solution Approach 2:
A dedicated robotic service device acts as an intermediary between the malfunctioning load handling devices and the maintenance system. This service device specializes in diagnostic, cleaning, and repair functions, allowing maintenance operations to proceed independently without stopping the entire automated storage system.
2Productivity
If the number of robotic load handling devices is increased to handle larger grids, then system capacity improves, but the likelihood of faults increases and the consequence of each fault grows
Solution Approach 1:
The maintenance function is segmented into a specialized robotic service device that operates independently from the load handling devices. This segmentation allows the service device to focus exclusively on monitoring and maintaining multiple load handling devices, reducing the overall fault impact by providing dedicated attention to each unit without requiring system-wide shutdowns.
Solution Approach 2:
The robotic service device continuously monitors the status of load handling devices through sensors and communication systems. When faults are detected, the service device receives feedback signals and responds by navigating to the malfunctioning device for diagnosis and repair, creating a closed-loop system that maintains high availability even as system capacity scales.
3Loss of time
If robotic service device is introduced for remote maintenance, then system downtime is reduced, but device complexity increases
Solution Approach 1:
The robotic service device is designed as a multi-functional platform that combines navigation, fault detection, diagnostic capabilities, cleaning mechanisms, and repair functions in a single unit. This universality allows one service device to handle multiple types of maintenance tasks across the entire grid, reducing the need for multiple specialized systems and minimizing the increase in overall complexity.
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
The top level of a frame structure (14), comprising a first set of rails (22a) extending in an X direction and a second set of rails (22b) extending in a Y direction, the X and Y directions being in a horizontal plane on the top level of the frame structure. Each rail in the first and second set of rails (22a, 22b) comprises a longitudinally extending dividing structure, centrally dividing the respective rail into two adjacent tracks, each track being engageable by a wheel of a robot service device (50).