Single-Grid Load Handling for High-Density Container Access
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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 and complex mechanisms, making them impractical for online retail and high-volume operations.
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 simultaneously and improving retrieval speed and efficiency.
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 due to wasted aisle space
Solution Approach 1:
The patent transitions from horizontal aisle-based access to vertical stack-based access. Containers are stacked vertically in columns, and retrieval is achieved by lifting stacks vertically rather than accessing them horizontally through aisles. This dimensional change eliminates the need for aisle space while maintaining full access to all containers, directly resolving the contradiction between accessibility and storage density.
2Quantity of substance
If complex hoisting mechanisms are used to access stacked containers, then storage density is improved, but device complexity and cost worsen
Solution Approach 1:
The system divides the storage structure into discrete vertical columns or stacks, each independently accessible. Instead of one complex mechanism serving the entire storage system, multiple simple lifting points are distributed across different columns. This segmentation allows each column to be accessed independently with simple lifting mechanisms, reducing overall system complexity while maintaining high storage density.
Solution Approach 2:
The stackable containers are designed with self-latching mechanisms and standardized interfaces that enable automatic stacking and secure positioning without complex mechanical assistance. The containers themselves provide the structural features needed for lifting and stacking, reducing the complexity of external hoisting mechanisms.
3Adaptability or versatility
If a rectangular tube load handler is used to grip containers at any level, then container retrieval flexibility is improved, but device footprint and storage system space requirements worsen
Solution Approach 1:
The patent replaces the horizontal rectangular tube mechanism with vertical lifting columns. Instead of extending horizontally to reach containers at different levels, the system uses vertical stacks where containers are accessed by lifting the entire stack or individual containers vertically. This dimensional change from horizontal to vertical operation dramatically reduces the device footprint while maintaining retrieval flexibility through multiple vertical stacking positions.
4Ease of operation
If single-product stacks are used to simplify retrieval operations, then ease of operation is improved, but storage efficiency deteriorates due to large floor area requirements
Solution Approach 1:
The patent implements multi-product stacks where each vertical column can contain different product types in different containers. The lifting mechanism is universal and can retrieve any container from any position in any stack without requiring dedicated single-product stacks. This multi-functionality allows maximum floor space utilization while maintaining operational simplicity through standardized vertical retrieval processes that work regardless of product composition.
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.