Single-Grid Load Handler for Dense Multi-Product Storage
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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 impractical for online retail businesses with vast product ranges, where single-product stacks are inefficient due to high space requirements and limited accessibility of items in multi-product stacks.
Innovation Solution
A load handling device with a reduced footprint that occupies only a single grid space in the storage system, allowing for efficient lateral movement and lifting of containers, enabling more devices to operate without obstructing each other, and facilitating faster retrieval of items from any stack level, including the bottom, by using a grid pattern of rails and a container-receiving space with integrated components.
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 patent transitions from horizontal aisle-based access to vertical stack-based access. Containers are stacked vertically in rows without requiring horizontal aisles, allowing robots to access containers from above. This dimensional change eliminates wasted aisle space while maintaining accessibility through vertical positioning and robotic retrieval mechanisms.
2Ease of operation
If a rectangular tube load handler is used to access containers at any level, then container accessibility is improved, but device height and space requirements increase
Solution Approach 1:
Instead of using a single large rectangular tube that spans the entire stack height, the patent segments the retrieval function into multiple smaller robotic units. Each robot operates independently within a reduced vertical envelope, using articulated arms or grippers to reach containers at different levels. This segmentation allows access to any container level without requiring a device as tall as the entire stack.
Solution Approach 2:
The patent employs dynamic robotic mechanisms with movable arms, joints, and adjustable grippers that can extend and reposition to reach containers at various heights. These dynamic components allow a compact robot body to access the full vertical range of stacked containers, eliminating the need for a static device as tall as the stack itself.
3Ease of operation
If single-product stacks are used, then retrieval simplicity is improved, but storage efficiency for diverse product lines deteriorates
Solution Approach 1:
The patent implements multi-product stacks where containers of different product types are stacked vertically together. The robotic retrieval system is designed to handle any container type and identify the correct container based on product information. This universal approach allows a single stack location to store multiple product lines, significantly improving storage efficiency while the robotic system maintains simple automated retrieval operations.
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.