Robotic Tote Storage Grid Layout for Dense, Serviceable Retrieval
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Solution Overview
Problem
Existing material handling systems in facilities face challenges in achieving high storage density, throughput, flexibility, modularity, scalability, and serviceability, leading to inefficiencies in processes such as item storage, retrieval, and shipping.
Innovation Solution
An automated storage and retrieval system utilizing robotic drive units and totes that traverse shelving systems via highway grids and elevators, equipped with imaging sensors and fiducial markers for navigation, enabling flexible and modular operation with multiple processing stations and service access zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional material handling systems are used, then operational simplicity is maintained, but storage density and throughput are insufficient
Solution Approach 1:
The system is divided into modular components including autonomous mobile robots, adjustable shelving units, and interchangeable totes. Each robot operates independently on highway grids, and shelving can be reconfigured in different patterns (e.g., U-shaped, linear) to optimize for different throughput requirements without redesigning the entire system.
Solution Approach 2:
The system employs dynamically adjustable elements including variable shelving heights, reconfigurable storage locations, and robots that can adapt their paths and operations in real-time. The control system dynamically assigns tasks to robots based on current system state and priorities, enabling flexible response to changing throughput demands.
2Quantity of substance
If storage density is increased, then space utilization improves, but accessibility and serviceability of components deteriorate
Solution Approach 1:
The high-density storage structure is segmented into modular shelving units that can be independently accessed and serviced. Robots can navigate to specific locations within the dense structure, and individual shelves or totes can be removed or adjusted without disrupting the entire storage system, maintaining serviceability despite high density.
Solution Approach 2:
The system incorporates automated monitoring and maintenance capabilities where robots can perform routine inspections and adjustments of shelving components. The control system tracks component status and can schedule maintenance during low-activity periods, enabling the system to service itself without extensive human intervention.
3Productivity
If automated robotic systems are implemented, then operational efficiency increases, but system flexibility and adaptability may be reduced
Solution Approach 1:
The robotic system is designed with universal capabilities where robots can perform multiple functions including transporting totes, adjusting shelving positions, and interacting with various storage configurations. The control system can assign different task types to the same physical robots, allowing the system to adapt to different operational requirements without adding specialized equipment.
Solution Approach 2:
The system maintains flexibility through dynamic task assignment and reconfigurable operations. Robots can change their behavior and paths in real-time based on control system instructions, and storage configurations can be dynamically adjusted to accommodate different item types and retrieval patterns, ensuring adaptability alongside automation.
4Adaptability or versatility
If modular and scalable design is implemented, then system adaptability improves, but device complexity increases
Solution Approach 1:
The system uses standardized modular components including identical robot platforms, interchangeable totes, and uniform shelving units. This segmentation allows components to be easily added, removed, or reconfigured without affecting the core system architecture, providing scalability while managing complexity through standardization.
Solution Approach 2:
Multiple functional elements are merged into integrated components where robots incorporate navigation, manipulation, and communication systems in single units. The control system merges task management, scheduling, and coordination functions into a unified software platform, reducing the apparent complexity despite the modular physical architecture.
Data Source
AI summary
Flexible, robotic automated storage and retrieval systems and processes may include one or more blocks of shelving systems, each block including a plurality of floors, and each floor including a plurality of storage grid locations for respective totes. A plurality of robotic drive units may traverse the storage grid locations using a plurality of highway grids and elevators to move totes between processing stations and storage grid locations. The freely movable robotic drive units and totes enable high flexibility, modularity, scalability, and serviceability of the flexible, robotic automated storage and retrieval systems.