Single-Grid Load Handler for Aisle-Free Container Retrieval
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Solution Overview
Problem
Existing storage systems face inefficiencies in storage density and accessibility, particularly in handling multiple product lines, as they require significant space for aisle access and are not well-suited for selecting single containers from multi-product stacks, making them impractical for online retail and high-volume operations.
Innovation Solution
A load-handling device designed to occupy a single grid space in a storage system, featuring a vehicle module with components housed above a container-receiving space, allowing for reduced footprint and efficient movement of containers within a grid frame structure, enabling faster and more efficient retrieval of containers from any stack level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are stacked in rows with aisle space for access, then product accessibility is improved, but storage density deteriorates
Solution Approach 1:
The system transitions from horizontal aisle-based access to vertical stack-based access. Containers are stacked vertically in rows without requiring horizontal aisle space, allowing robots to access containers from above by lowering them vertically onto the stacks. This dimensional change eliminates the trade-off between accessibility and storage density.
2Adaptability or versatility
If a rectangular tube load handler is used to grip containers at any level, then container retrieval flexibility is improved, but device height requirement increases
Solution Approach 1:
The load handler is divided into separate functional modules: a robot controller positioned above the stacks and a gripper mechanism that lowers vertically onto containers. This segmentation allows the control system to be positioned high for optimal visibility and control, while the gripper can reach any container level by extending downward, eliminating the need for a single tall rectangular tube structure.
Solution Approach 2:
A vertical lowering mechanism acts as an intermediary between the robot controller above and the containers at various levels. This intermediary component enables the robot to access containers at any height without requiring the entire robot structure to be as tall as the highest container stack.
3Ease of operation
If single-product stacks are used to simplify retrieval, then retrieval operation simplicity is improved, but floor area requirement increases
Solution Approach 1:
The load handler and robot system are designed to handle multi-product stacks with the same ease as single-product stacks. The gripper mechanism can identify and retrieve specific containers based on product information, eliminating the need to separate containers into single-product stacks. This multi-functionality allows the system to maintain operational simplicity while maximizing floor space utilization.
Data Source
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Figure 3a
AI summary
A storage system and a load handling device for lifting and moving containers stacked in the storage system are described. The storage system includes a plurality of rails or tracks (22a, 22b) arranged in a grid pattern (14) above the stacks of containers. The grid pattern comprises a plurality of grid spaces and each stack is located within a footprint of only a single grid space. The load handling device is configured to move laterally on the rails or tracks above the stacks. The load handling device includes a container receiving space located above the rails or tracks in use and a lifting device arranged to lift a container from a stack into the container receiving space. The load handling device comprises a mechanism for enabling lateral movement of the device in one of two transverse directions by enabling either a first or second set of wheels to selectively engage the first or second set of rails or tracks (22a or 22b).