Shuttle-Satellite Bin Storage Layout for Dense Hygienic Retrieval
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Solution Overview
Problem
High-volume food production faces challenges in efficiently managing raw material storage with strict temperature, cleanliness, and timeliness requirements, particularly for meat and poultry products, while maintaining accurate tracking and hygiene.
Innovation Solution
An automated storage system utilizing self-propelled vehicles and lifting devices to manage dense storage of bins, ensuring precise handling and hygiene through stainless steel construction and contactless identification, with a control system for real-time tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bins are stored in a traditional storage facility, then storage capacity is limited, but the storage space utilization is low and temperature control efficiency is poor
Solution Approach 1:
The storage system transitions from traditional horizontal storage to a three-dimensional rack-based system with multiple levels. Bins are stored vertically on racks with multiple tiers, allowing the system to utilize vertical space and dramatically increasing storage capacity within the same footprint without proportionally increasing system complexity
Solution Approach 2:
The system implements a hierarchical nested structure where satellite vehicles operate within aisles formed by racks, shuttle vehicles transport satellite vehicles between stations, and lifting devices move bins vertically. This nested arrangement maximizes space utilization while organizing complexity in manageable layers
2Productivity
If manual handling of bins is used, then operation simplicity is maintained, but productivity is low and hygiene requirements are difficult to meet
Solution Approach 1:
The system employs autonomous self-propelled satellite vehicles that navigate aisles independently to locate and transport bins. These vehicles self-manage their movement and bin handling operations without requiring manual intervention, thereby increasing productivity while maintaining ease of operation through automated control
Solution Approach 2:
Manual mechanical handling of bins is replaced with an automated system combining self-propelled vehicles, robotic lifting devices, and centralized control systems. This substitution dramatically increases handling efficiency and productivity while the centralized control maintains operational simplicity through automated coordination
3Reliability
If traditional storage racks are used, then system simplicity is maintained, but temperature control and hygiene maintenance are insufficient
Solution Approach 1:
The storage system implements localized temperature control within individual rack aisles and bin locations rather than uniform cooling throughout. Each aisle or storage zone can be independently monitored and controlled, ensuring reliable temperature maintenance for perishable goods while the modular design prevents excessive overall system complexity
Solution Approach 2:
The system incorporates sensors and monitoring devices that continuously track temperature, humidity, and bin locations, feeding this data back to the control system. This feedback mechanism ensures reliable temperature control by enabling real-time adjustments, while the automated monitoring reduces the complexity of manual surveillance
4Area of stationary object
If dense storage arrangement is implemented, then space utilization is improved, but accessibility and retrieval speed may be affected
Solution Approach 1:
The system uses dynamic self-propelled satellite vehicles that can autonomously navigate to any aisle and position themselves to retrieve bins. This dynamic capability allows dense storage arrangements while maintaining fast retrieval times, as vehicles can directly access any stored bin without manual intervention or fixed positioning constraints
Solution Approach 2:
Shuttle vehicles act as intermediaries between storage aisles and retrieval stations, transporting satellite vehicles efficiently between locations. This intermediary system enables dense storage by coordinating vehicle movements and minimizing retrieval time through optimized transport routes and centralized dispatch
Data Source
AI summary
An automated storage comprising a storage rack configured to store storage bins, a self-propelled shuttle vehicle configured to move along the first horizontal direction of the storage rack, a self-propelled satellite vehicle configured to be carriable by the self-propelled shuttle vehicle and configured to move along the second horizontal direction of the storage rack essentially perpendicular against the first horizontal direction, wherein the self-propelled satellite vehicle is configured to carry storage bin between the self-propelled shuttle vehicle and the storage position; wherein the self-propelled satellite vehicle comprises at least one groove on the top surface of the self-propelled satellite vehicle, a pair of mutually facing guides along the second horizontal direction wherein the self-propelled satellite vehicle is configured to move on top of the pair of mutually facing guides, a pair of mutually facing bars along the second horizontal direction essentially above the said pair of mutually facing guides wherein the storage bin is to be placed on top of the pair of mutually facing bars by the lifting lugs of the storage bin.