Single-Grid Load Handler for Dense Stack Container Access
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Solution Overview
Problem
Existing storage systems face inefficiencies in storage density and accessibility, particularly for online retail businesses handling tens of thousands of different product lines, as they require large floor areas and are not well-suited for selecting single containers from multi-product stacks, leading to impractical use of single-product stacks and inefficient storage solutions.
Innovation Solution
A load-handling device designed to occupy a single grid space in a storage system, featuring a vehicle with a reduced footprint that includes a lifting mechanism with a gripper device capable of gripping containers from above, allowing lateral movement and vertical lifting, enabling efficient retrieval of containers from any stack level without obstructing other devices, thus improving storage system efficiency and accessibility.
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 patent transitions from horizontal aisle-based access to vertical stack-based access. Containers are stacked vertically in rows without aisles, and access is achieved by lifting stacks vertically rather than moving laterally through aisles. This dimensional change eliminates wasted aisle space while maintaining accessibility.
Solution Approach 2:
The patent extracts the access path from the storage system by removing aisles entirely. Instead of requiring lateral movement through aisles to reach containers, the system allows direct vertical access to any container in a stack by lifting the entire stack or individual containers from the top.
2Quantity of substance
If free-standing stacks of containers are used, then storage density is improved, but device complexity deteriorates
Solution Approach 1:
The patent segments the hoisting function into modular components: a load handler with a movable tube that can grip individual containers or multiple containers at different levels. This segmentation allows simpler, more flexible access mechanisms compared to complex centralized hoisting systems.
Solution Approach 2:
The load handler employs dynamic, movable tubes that can extend and retract to reach containers at any level in a stack. This dynamic structure replaces complex fixed hoisting mechanisms with simpler, adaptable components that can service multiple stack heights.
3Ease of operation
If a rectangular tube load handler is used to access containers, then container accessibility is improved, but the height of the system is restricted
Solution Approach 1:
The load handler uses dynamically extendable tubes that can reach containers at any level within the stack. The tube length adjusts based on the stack height and container position, allowing access to tall stacks without requiring the entire load handler to be as tall as the maximum stack.
Solution Approach 2:
The movable tube acts as an intermediary between the load handler body and the containers. It extends to reach containers at various heights and retracts when not in use, allowing the load handler to service stacks taller than the handler itself without requiring proportional height.
4Productivity
If single-product stacks are used, then container retrieval efficiency is improved, but floor area requirement deteriorates
Solution Approach 1:
The patent enables stacks to serve multiple functions: they can be single-product stacks for efficient bulk storage and retrieval, or multi-product stacks for space-efficient storage of diverse items. The load handler is designed to service both types of stacks, making the system universally applicable to different storage strategies.
Solution Approach 2:
The system allows dynamic changes in stack composition and configuration. Stacks can be reconfigured from single-product to multi-product arrangements based on storage needs, and the load handler adapts its operation accordingly, enabling flexible use of floor space while maintaining retrieval efficiency.
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 arranged in a grid pattern above the stacks of containers. The grid pattern has a plurality of grid spaces and each stack is located within a footprint of a single grid space. The load handling device can move laterally on the rails above the stacks and includes a container receiving space located above the rails in use and a lifting device arranged to lift a container from a stack into the container receiving space. The load handling device also includes 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.