Sensor-Linked Storage Containers for Dense Stack Access
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Solution Overview
Problem
Existing storage systems that rely on stacked containers lack active components and intelligent monitoring, leading to inefficiencies in managing and maintaining the conditions of stored goods, particularly in densely packed environments where access and control of individual containers are limited by the need for complex hoisting mechanisms and restricted height due to robotic load handlers.
Innovation Solution
A storage system featuring a grid pattern of rails with robotic load handling devices and containers equipped with service means, including sensors, data logging, and communication capabilities, allowing for condition monitoring and control of temperature, lighting, and other parameters, enabling peer-to-peer communication and service provision between containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If containers are arranged in densely packed stacks to increase storage capacity, then storage density is improved, but access to individual containers becomes difficult and requires complex hoisting mechanisms
Solution Approach 1:
The patent replaces complex mechanical hoisting mechanisms with a robotic system comprising an autonomous mobile robot equipped with sensors and manipulators. The robot navigates to containers using sensor data and retrieves them through automated manipulation, eliminating the need for traditional hoisting infrastructure while maintaining access to densely stacked containers.
Solution Approach 2:
Containers are equipped with embedded identifiers, sensors, and communication devices that enable them to be self-identified and self-monitored. The robotic system autonomously detects container locations and conditions through sensors, and containers provide their own status information, reducing the need for external monitoring and manual intervention.
2Device complexity
If traditional passive containers are used to reduce system complexity, then device complexity is reduced, but monitoring and control capabilities are insufficient
Solution Approach 1:
The patent implements multi-functionality by integrating various services into the container-robot system. Containers serve not only as storage vessels but also as nodes in a communication network, carrying sensors, identifiers, and communication devices. The robotic system performs multiple functions including navigation, container manipulation, condition monitoring, and data collection, replacing multiple separate systems with a unified platform.
Solution Approach 2:
The patent applies nesting by embedding electronic components (sensors, identifiers, communication devices) within the containers, and nesting the robotic system within the storage facility infrastructure. The robot contains sensors that detect container conditions, which are then processed and communicated through hierarchical levels of the system.
3Device complexity
If robotic load handlers with fixed height constraints are used, then system structure is simplified, but maximum stack height is restricted reducing storage efficiency
Solution Approach 1:
The patent transitions from fixed-height robotic handlers to a dynamic autonomous mobile robot system. The robot can adapt its navigation path and manipulation strategy based on real-time sensor data about container positions and stack configurations. This dynamic approach allows retrieval from varying stack heights without requiring the entire system to conform to a fixed height constraint.
Solution Approach 2:
The patent moves the retrieval mechanism from a vertical constraint model to a three-dimensional autonomous navigation model. Instead of being limited by the vertical reach of a fixed handler, the robot navigates through three-dimensional space using sensors to detect and access containers at any position within the storage volume, effectively utilizing the third dimension for movement and access.
Data Source
AI summary
A storage system is described where goods are stored in containers and the containers are stored in stacks. Above the stacks runs a grid network of tracks on which load handling devices run. The load handling devices take containers from the stacks and deposit then at alternative locations in the stacks or deposit then at stations where goods may be picked out. Each container may be provided with connectors having a push fit male connector located at a top edge of the container and a female connector at a bottom edge of the container. Adjacent containers in a stack can be linked by routing means, which form moldings on each container. The connectors can also have spring-loaded contacts. The provision of these services within individual containers rather than across the system as a whole, allows for flexibility in storage whilst reducing cost and inefficiency.