Shuttle Control Device for Multi-Deep Storage Channel Blockage Prevention
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Solution Overview
Problem
Shuttle systems often experience blockage situations and low storage densities due to delays in conveying goods and inadequate control over storage location assignment, leading to inefficiencies and reduced throughput.
Innovation Solution
Implementing a control device that manages shuttle operations by checking for open orders and modifying or assigning orders to prevent simultaneous access to the same storage channel, specifying storage locations only when the shuttle arrives, and using sensors to determine available storage spaces, thereby optimizing storage density and preventing blockages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple shuttles operate simultaneously in the same level to increase throughput, then productivity improves, but blockage situations occur when shuttles attempt to access the same storage channel
Solution Approach 1:
The control device checks for open orders and performs preliminary actions to prevent blockages before they occur. When a shuttle is assigned to a storage channel, the system proactively manages order sequencing and shuttle coordination to ensure that subsequent shuttles do not create blocking situations, thereby maintaining both high throughput and reliable operation.
2Productivity
If storage locations are assigned in advance to shuttles, then order processing efficiency improves, but storage density decreases due to delays in conveying goods
Solution Approach 1:
The system dynamically adjusts storage location assignment based on real-time conditions. Instead of static pre-assignment, the control device monitors shuttle positions, conveying delays, and storage channel availability, making adaptive decisions about which storage locations to assign to which shuttles. This dynamic approach maintains efficient order processing while maximizing storage density by utilizing previously idle locations.
3Quantity of substance
If the control device manages all storage location assignments centrally, then storage density optimization improves, but device complexity increases
Solution Approach 1:
Shuttles are equipped with sensors that enable them to autonomously detect and report their positions and the status of storage locations. This self-service capability reduces the burden on the central control device, as shuttles provide their own operational data. The control device leverages this information for centralized optimization decisions, achieving high storage density without proportionally increasing control system complexity.
Data Source
AI summary
A method and system for operating a shuttle system by a control device are disclosed. The shuttle system comprises a rack with a driveway and a multi-deep storage channel with at least two storage locations. In embodiments, the shuttle system comprises at least two shuttles arranged to store, retrieve, or transfer conveyed goods; the shuttles receive orders from the control device. Once an active order for a conveyed good in a specific storage channel is present, the control device checks whether an open order for storing, retrieving, or transferring in this storage channel is present. If no open order is present, the control device places the active order. If an open order is present, the control device either assigns the active order only after the open order has been completed, or modifies the active order so that a storage channel is selected for which no open order is present.