Service Vehicle Control for Removing Failed ASRS Rail Shuttles

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Solution Overview

Problem

Existing automated storage and retrieval systems face challenges in accessing and maintaining malfunctioning container handling vehicles on rail systems without shutting down the entire system, which is costly and risky for personnel.

Innovation Solution

The system employs a dual control system with independent communication networks to manage container handling vehicles and a service vehicle. The main control system identifies malfunctioning vehicles, sets up exclusion zones, and reroutes other vehicles, while the secondary control system independently manages the service vehicle to safely remove the malfunctioning vehicle without shutting down the system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire system is shut down to access and maintain malfunctioning vehicles, then personnel safety is ensured, but operational productivity is lost and system downtime increases

Engineering Contradiction:

Improvepersonnel safetyVSAvoidsystem operational continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The control system is segmented into a main control system for normal vehicle operations and a secondary control system specifically for service vehicle operations. This segmentation allows the service vehicle to operate independently on the rail system without requiring shutdown of the entire system, thereby maintaining productivity while ensuring personnel safety through dedicated control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A service vehicle acts as an intermediary between personnel and malfunctioning vehicles. The service vehicle autonomously navigates the rail system under secondary control system management to reach, service, and retrieve malfunctioning vehicles, eliminating the need for personnel to physically access the rail system during operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the system continues to operate while servicing malfunctioning vehicles, then productivity is maintained, but access to malfunctioning vehicles becomes difficult and complex

Engineering Contradiction:

Improvesystem operational continuityVSAvoidaccess to malfunctioning vehicles

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The service vehicle is equipped with a cradle mechanism that autonomously engages with malfunctioning vehicles to immobilize and secure them. The service vehicle then transports the malfunctioning vehicle to a service area where maintenance personnel can safely access it, eliminating the complexity of manual access procedures while the system continues to operate.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If a dual control system with independent communication networks is implemented, then service vehicle operations can proceed independently, but system complexity increases

Engineering Contradiction:

Improveindependent service vehicle controlVSAvoiddual control system architecture

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The communication network is segmented into a first communication network for the main control system and a second communication network for the secondary control system. This segmentation enables independent operation of the service vehicle while maintaining clear separation of control functions, managing complexity through modular architecture.

Inventive Principle:

Principle #1Segmentation

4Productivity

If malfunctioning vehicles are removed without system shutdown, then operational costs are reduced, but safety risks for personnel increase

Engineering Contradiction:

Improveoperational cost reductionVSAvoidpersonnel safety risks

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The service vehicle serves as a protective intermediary that isolates personnel from hazardous rail system environments. By transporting malfunctioning vehicles to service areas and performing maintenance operations remotely, the system maintains productivity and reduces costs while eliminating direct personnel exposure to safety risks.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12283137B2System, method and main control system for handling malfunctioning vehicles in an automated storage and retrieval system comprising a rail system

Publication Date: 2025.04.22 AUTOSTORE TECH AS

AI summary

An automated storage and retrieval system includes a rail system with perpendicular tracks in X and Y direction. The storage and retrieval system includes a plurality of remotely operated container handling vehicles configured to move laterally on the rail system; and a main control system using a first communication system for communicating with the plurality of remotely operated container handling vehicles. The main control system monitors and controls the movement of the plurality of container handling vehicles via the first communication system. At least one service vehicle is movable on the rail system. The at least one service vehicle is configured to bring a malfunctioning remotely operated container handling vehicle to a service area outside of the rail system where the remotely operated container handling vehicles operate. The system further includes a secondary control system using a second communication system. The second communication system is independent of the main communication system. The secondary control system is communicating with the at least one service vehicle on the rail system such as to monitor and control the movement of the at least one service vehicle.