Shuttle Shelf Rescue Mode for Power-Outage Vehicle Recovery
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Solution Overview
Problem
Energy-autonomous vehicles in automated warehouse systems lose control during power outages, leading to safety concerns and requiring manual intervention for system restart due to their limited operational time without communication.
Innovation Solution
Implementing a rescue mode where vehicles autonomously return to charging stations after a predetermined time period, ensuring they are in a controlled state for system restart, and using initial pairing data stored in non-volatile memory to verify their positions and enable automatic reconfiguration without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If energy-autonomous vehicles are used in automated warehouse systems, then operational flexibility and autonomy are improved, but safety control and system reliability deteriorate during power outages
Solution Approach 1:
The system performs preliminary actions by automatically returning vehicles to charging stations and recharging them during power outages before manual intervention is needed. The controller autonomously manages vehicle positioning and energy replenishment, ensuring vehicles are ready for immediate resumption of operations without requiring technician intervention.
Solution Approach 2:
Vehicles serve themselves by autonomously navigating to charging stations and recharging without external assistance. The system enables self-service operation where vehicles manage their own energy needs and positioning during power interruptions, maintaining operational continuity without human intervention.
2Reliability
If vehicles are required to return to charging stations after power restoration, then system reliability is improved, but operational time is lost
Solution Approach 1:
The system maintains continuity of useful action by performing vehicle return and recharging operations automatically during power outages. When power is restored, vehicles are already positioned and recharged, allowing immediate resumption of material handling operations without interruption or downtime.
Solution Approach 2:
The controller performs preliminary actions by returning vehicles to charging stations and recharging them before power restoration is complete. This advance preparation ensures vehicles are ready for immediate operation upon power return, eliminating delays and maintaining operational continuity.
3Object-affected harmful factors
If manual intervention is required for system restart after power failure, then safety is ensured, but productivity is reduced
Solution Approach 1:
The system performs self-service by automatically managing vehicle return, positioning, and recharging operations during and after power outages. The controller autonomously coordinates these tasks without requiring manual intervention, enabling rapid system recovery while maintaining safety through controlled autonomous operations.
Solution Approach 2:
The system maintains continuity of useful action by automatically resuming operations immediately upon power restoration without requiring manual intervention. The controller continuously manages vehicle operations, ensuring safe yet rapid system recovery and minimizing productivity loss from power interruptions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures safe and automated system restart by verifying vehicle positions and recharging, eliminating the need for manual inspection and reducing downtime.
Implementation Method 1
Energy-autonomous vehicles have an on-board energy storage unit and are not permanently connected to the energy source. The on-board energy storage unit is charged in or at so-called charging stations.
Data Source
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AI summary
An automated storage system (10) is disclosed comprising: a racking arrangement (18) with two racks (20) defining a racking aisle (22) between them, the racks (20) having several racking levels (R) vertically stacked one above the other; energy-autonomous vehicles (12) arranged in the racking aisle (22) in the racking levels (R) and which are horizontally movable for the automated storage and retrieval of stored goods, each of the vehicles (12) being initially configured and comprising a vehicle controller (36), an energy storage device (38) and a data storage device (26); and a system controller (16) that communicates with each of the vehicle controllers (36);wherein each of the vehicle controllers (36) is configured: to cause the corresponding vehicle (12) to switch to an autonomous rescue mode and automatically drive to an assigned charging station (14) if communication between the corresponding vehicle controller (36) and the system controller (16) is interrupted for longer than a first predetermined time period T1, in particular due to a power failure of the system (10); and to initiate a pairing process as soon as communication with the system controller (16) is restored. (Fig. 5);