Shared Robotic Fleet Linking 3D ASRS and Manufacturing Cells
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Solution Overview
Problem
Conventional manufacturing facilities face challenges in adapting to changing conditions, requiring extensive conveyors and fixed workflows, leading to inefficiencies and downtime, with ASRSs disconnected from manufacturing cells and relying on one-way conveyors, resulting in complex logistics and large footprints.
Innovation Solution
An interconnected automated storage and retrieval system (ASRS) with a common fleet of robotic storage/retrieval vehicles (RSRVs) navigates within a 3D array to deliver componentry to various manufacturing cells, allowing flexible configuration and just-in-time delivery, eliminating the need for long-range conveyors and enabling seamless access to inventory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional one-way conveyor systems are used to connect manufacturing cells, then material flow is established, but system flexibility and adaptability to changing conditions deteriorate
Solution Approach 1:
The patent implements dynamic, bidirectional robotic vehicles that can change direction and routing in real-time based on manufacturing needs, replacing static one-way conveyors. The vehicles navigate freely between storage structures and manufacturing cells, allowing the system to adapt to changing production requirements without physical reconfiguration.
Solution Approach 2:
The robotic vehicles serve multiple functions: transporting materials bidirectionally, navigating complex 3D pathways, interfacing with both storage and manufacturing systems, and adapting to different routing requirements. This multi-functional approach eliminates the need for dedicated conveyors for each function, reducing overall system complexity.
2Area of stationary object
If ASRS structures are disconnected from manufacturing cells with extensive conveyors, then material storage is achieved, but space efficiency and service integration deteriorate
Solution Approach 1:
The patent utilizes three-dimensional vertical pathways and multi-level storage structures, allowing robotic vehicles to access materials from any level and deliver them directly to manufacturing cells. This vertical integration eliminates the need for extensive horizontal conveyor systems, maximizing floor space utilization while maintaining direct service connectivity.
Solution Approach 2:
The system merges the storage and manufacturing zones by allowing robotic vehicles to operate seamlessly between ASRS structures and manufacturing cells without intermediate conveyor transfers. This direct integration consolidates previously separate functions into a unified system, improving both space efficiency and service coordination.
3Adaptability or versatility
If fixed conveyor paths are used for material delivery, then material transport is established, but delivery flexibility and sequencing capability deteriorate
Solution Approach 1:
The robotic vehicles dynamically select and change delivery paths in real-time based on priority, destination, and current system state. Multiple vehicles can service the same destination with different routing options, allowing flexible sequencing and immediate adaptation to changing delivery requirements without reprogramming fixed conveyors.
Solution Approach 2:
The autonomous robotic vehicles act as intelligent intermediaries between the central control system and physical material transport. They receive high-level delivery instructions and autonomously navigate, route, and execute deliveries, eliminating the need for time-consuming reprogramming of fixed conveyor systems while maintaining centralized coordination.
4Productivity
If scattered manufacturing zones with long-range conveyors are used, then process separation is achieved, but system footprint and equipment requirements deteriorate
Solution Approach 1:
The patent implements vertical stacking of manufacturing cells and storage structures with 3D robotic access, allowing multiple manufacturing processes to occur in overlapping vertical spaces rather than requiring extensive horizontal separation. This reduces the facility footprint while maintaining process independence and productivity through robotic material delivery.
Data Source
AI summary
A manufacturing system including an automated storage and retrieval system (ASRS) structure with a three-dimensional array of storage locations distributed throughout a two-dimensional footprint of the ASRS structure at multiple storage levels; workpieces stored within the storage locations of the ASRS structure; robotic storage/retrieval vehicles (RSRVs) navigable within the ASRS structure in three dimensions to access the storage locations, and multiple manufacturing cells positioned outside the ASRS structure, is provided. The manufacturing system includes a track structure attached to the ASRS structure and defining one or more travel paths traversable by the RSRVs from the ASRS structure. The same fleet of RSRVs that is navigable within the ASRS structure is operable to deliver the workpieces to the manufacturing cells. One or more of the manufacturing cells are positioned along the track structure, thereby receiving convenient access to the workpieces along with associated tool pieces and workpiece supports for manufacturing goods.