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 specific containers from multi-product stacks, especially in enclosed spaces like warehouses.
Innovation Solution
The development of load handling devices that occupy only a single grid space in a storage system, featuring a compact design with a container-receiving space and a lifting device, allowing lateral movement and efficient retrieval of containers from stacked systems, reducing the footprint and enabling more devices to operate without obstructing each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are stacked in rows with aisles 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. Load handling devices operate from above the stacks, retrieving containers by lowering them onto the devices. This vertical dimension eliminates the need for horizontal aisles, allowing containers to be stacked directly on top of each other without requiring lateral access paths, thereby dramatically improving storage density while maintaining accessibility.
2Adaptability or versatility
If a rectangular tube load handler is used to access containers at any stack level, then container retrieval capability is improved, but device height requirement increases
Solution Approach 1:
The load handling device segments the container retrieval process into distinct phases: (1) lateral movement to the target stack position, (2) vertical lowering of the gripper to the required container level, and (3) container grasping and lifting. This segmentation allows the device to access containers at any height without requiring the entire device structure to be as tall as the maximum stack, since only the gripper component needs to extend vertically, not the entire load handler.
Solution Approach 2:
The system introduces an intermediary vertical movement mechanism between the lateral positioning function and the container grasping function. The load handling device laterally positions itself at the base of the stack, then uses a vertical lowering mechanism to reach the target container level. This intermediary vertical translation mechanism enables access to any stack level without requiring the device's overall height to match the stack height.
3Productivity
If load handling devices have large footprints, then container handling capacity is improved, but system space utilization deteriorates
Solution Approach 1:
The load handling device merges multiple functions into a single integrated unit: lateral movement along rails, vertical positioning, container grasping, and lifting. By combining these functions into one compact device rather than using separate mechanisms, the system achieves full container handling capability within a minimal footprint, allowing devices to operate efficiently in close proximity without requiring large individual footprints.
Data Source
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 arranged in a grid pattern above the stacks of containers. The grid pattern can include 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 has a footprint that, in use, occupies only a single grid space in the storage system.