Shuttle Rack Storage Layout With Double-Cycle Lifter Transfer
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Solution Overview
Problem
Existing storage systems face challenges in achieving high performance with reduced costs and space requirements, often bottlenecked by shuttle lifts or conveyor technology, and require complex sequencing and inefficient use of lifting devices.
Innovation Solution
A method and system utilizing bidirectional shuttles and lifts with double cycles, incorporating buffer lanes and efficient vertical transport between rack levels, minimizing the need for lifts and buffer positions, and enabling flexible workstation configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional conveyor technology and multiple lifters are used to achieve high throughput, then productivity is improved, but device complexity and costs increase
Solution Approach 1:
The patent combines multiple lifter functions into a single lifter by implementing double cycles that perform both storage (transporting containers from level 1 to level 2) and retrieval (transporting containers from level 2 to level 1 or from level 3 to level 1) operations. This merging eliminates the need for separate lifters for different operations, reducing device complexity while maintaining high throughput capability.
Solution Approach 2:
The lifter operates continuously without idle traverses by immediately following a vertical transport from level 1 to level 2 with another vertical transport from level 2 or 3 back to level 1 or 4. This continuous operation eliminates empty runs, maximizing productivity while using minimal equipment.
2Productivity
If multiple lifters are deployed to handle high throughput operations, then productivity is improved, but the space requirements and costs increase
Solution Approach 1:
Multiple lifter functions are merged into a single lifter through double cycle operations, eliminating the need for multiple lifters that would occupy significant vertical and horizontal space. The single lifter handles all vertical transport needs for both storage and retrieval operations.
Solution Approach 2:
The single lifter is designed to perform multiple functions: transporting containers from level 1 to level 2 for storage, transporting containers from level 2 to level 1 for retrieval, and transporting containers from level 3 to level 1. This multi-functionality reduces the number of equipment pieces needed, thereby reducing space requirements.
3Productivity
If conventional storage systems with complex conveyor technology are used, then high throughput is achieved, but costs increase
Solution Approach 1:
The patent extracts and eliminates complex conveyor technology from the system, replacing it with a simplified architecture where bidirectional shuttles transport containers directly between storage locations and a single lifter handles all vertical transport. This extraction of unnecessary complexity significantly reduces manufacturing costs while maintaining throughput capability.
Solution Approach 2:
The system uses simple, cost-effective components: bidirectional shuttles that can change levels by climbing and a single lifter, replacing expensive conventional conveyor systems and multiple lifters. The simplified design reduces both initial manufacturing costs and ongoing maintenance costs.
4Adaptability or versatility
If bidirectional shuttles change levels using shuttle lifts, then adaptability is improved, but the shuttle lift becomes a bottleneck for high throughput
Solution Approach 1:
The level-changing function is segmented and reassigned: bidirectional shuttles perform level changing by climbing between rack levels using their own climbing capability, while the single lifter handles vertical transport of containers between levels. This segmentation eliminates the shuttle lift bottleneck, as shuttles can independently change levels without waiting for a shared lift resource.
Solution Approach 2:
Bidirectional shuttles serve themselves by using their own climbing mechanism to change levels independently, rather than relying on a shared shuttle lift. This self-service capability eliminates the bottleneck, allowing multiple shuttles to operate in parallel at different levels simultaneously, thereby increasing throughput.
Data Source
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AI summary
With a view to high performance at reduced costs and reduced space requirements, a method for storing and/or retrieving a stored good (3) in or from a storage system, in particular a storage and retrieval system, is described, comprising a rack storage system (2) with several spaced-apart storage racks (1), wherein the storage racks (1) have one or more storage locations (4) for a stored good (3) in several superimposed rack levels (10) and wherein a rack aisle (5) is formed between adjacent storage racks (1), at least one bidirectional shuttle (6) for transporting stored good (3) or containers (7) for the stored good (3) to or from a storage location (4), wherein the shuttle(s) (6) are designed to travel on aisle sections (8) formed in the rack aisles (5), preferably by guide rails, in one rack level (10) and to travel on one or more of the aisle sections (8), preferably at the ends of the rack aisles (5).connecting connecting sections of the rack storage system (2) is or are formed, and at least one lifter (11) arranged adjacent to an aisle section (8) or connecting section, wherein the at least one lifter (11) is designed for transferring and/or receiving a stored item (3) or a container (7) for a stored item (3) to and/or from a shuttle (6) and for the vertical transport of a stored item (3) or a container (7) between rack levels (10), wherein the lifter (11) transports a stored item (3) or one or more containers (7) from the second rack level (10) or from a third rack level (10) adjacent to the second rack level (10) to the first rack level (10) or to a fourth rack level (10) directly following a vertical transport of a stored item (3) or one or more containers (7) from a first rack level (10) to a second rack level (10). Furthermore, a corresponding storage system is specified.