Selective-Wheel Load Handler for Aisle-Free Container Stacks
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Solution Overview
Problem
Existing storage systems face inefficiencies in storage density and accessibility, particularly for online retail businesses handling tens of thousands of different product lines, as they require large floor areas and complex retrieval mechanisms, limiting the use of single-product stacks and restricting the height of container stacks in enclosed spaces.
Innovation Solution
A load-handling device with a reduced footprint, featuring a vehicle with components housed above a container-receiving space, allowing lateral movement on a grid pattern of rails and equipped with a lifting mechanism to grip containers from above, enabling efficient retrieval and movement of containers from any stack level without obstructing other devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are stacked in rows with aisles for access, then product accessibility is improved, but storage density deteriorates
Solution Approach 1:
The system transitions from horizontal aisle-based access to vertical stack-based access. Containers are stacked vertically in columns, and retrieval is achieved by moving load handling devices vertically along the stacks rather than horizontally through aisles. This dimensional change eliminates the need for aisle space while maintaining full access to all containers.
2Ease of operation
If a rectangular tube load handler is used to access containers at any stack level, then container accessibility is improved, but device height and space requirements increase
Solution Approach 1:
The load handling system is segmented into modular units that can operate independently on each stack. Rather than requiring a single tall tube to reach all levels, the system uses multiple load handlers that can service different portions of stacks, reducing the height requirement for each individual device.
Solution Approach 2:
The load handling devices incorporate movable components including extendable arms and adjustable gripping mechanisms that can dynamically reach different heights and positions on the stacks. This dynamic capability allows compact devices to access containers at various levels without requiring fixed tall structures.
3Productivity
If single-product stacks are used to simplify retrieval, then retrieval speed is improved, but floor area requirements increase
Solution Approach 1:
The load handling devices are designed with universal capabilities to handle multiple product types and container configurations. The systems can selectively retrieve containers based on product type, order requirements, or stack location, enabling multi-product stacks to be managed efficiently without sacrificing retrieval speed. This multi-functionality allows consolidation of multiple single-product stacks into fewer multi-product stacks.
4Quantity of substance
If container stacks are made taller to increase storage density, then storage capacity is improved, but accessibility to lower containers deteriorates
Solution Approach 1:
The load handling device acts as an intermediary mechanism between the retrieval system and containers at various heights. Equipped with extendable arms, adjustable grippers, and vertical movement capabilities, the device can reach containers at any level of tall stacks without requiring physical access from the side or bottom, thus maintaining accessibility while enabling increased stack height.
Data Source
AI summary
A storage system includes a plurality of rails or tracks arranged in a grid pattern above the stacks of containers. The grid pattern includes a plurality of grid spaces and each stack is located within a footprint of only a single grid space. A load handling device is configured to move laterally on the rails or tracks above the stacks. The load handling device includes a container receiving space located above the rails or tracks in use and a lifting device arranged to lift a container from a stack into the container receiving space. The load handling device includes a mechanism for enabling lateral movement of the device in one of two transverse directions by enabling either a first or second set of wheels to selectively engage the first or second set of rails or tracks.