Automated Storage Controller Rule-Based Placement
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Solution Overview
Problem
Current automated storage and retrieval systems rely on Warehouse Management Systems (WMS) for detailed control of storage locations, which results in performance penalties and inflexibility, as they select random storage columns for storage containers without considering specific product types or storage rules, potentially leading to inefficient storage and safety issues.
Innovation Solution
A method and system where the main controller of the automated storage and retrieval system determines specific storage locations for storage containers based on their content codes and associated storage rules, allowing for flexible and rule-based placement of products, including considerations for type, quantity, and safety parameters, such as distance between flammable or valuable items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the WMS controls storage locations randomly without considering product types or storage rules, then the system operation is simple, but storage efficiency and safety are reduced
Solution Approach 1:
The patent extracts the storage location control function from the WMS to a dedicated main controller. The main controller specifically handles storage rule evaluation and location determination, while the WMS focuses on high-level warehouse management. This separation allows the WMS to remain simple while achieving efficient and safe storage through the specialized main controller that processes content codes and applies storage rules.
Solution Approach 2:
The main controller acts as an intermediary between the WMS and the storage containers. It receives container information from the WMS, evaluates storage rules based on content codes, determines optimal storage locations, and directs container placement. This intermediary layer enables complex storage logic without burdening the WMS system.
2Reliability
If the WMS determines storage locations without considering storage rules, then the system is flexible and adaptive, but safety and compliance are compromised
Solution Approach 1:
The system dynamically adapts storage strategies based on product types and storage rules. The main controller evaluates content codes to determine appropriate storage locations, considering factors like product compatibility, accessibility requirements, and safety constraints. This dynamic approach allows the system to be both safe (compliant with storage rules) and flexible (adaptable to different product types and changing conditions).
Solution Approach 2:
The system changes storage parameters (location, depth, accessibility) based on product characteristics encoded in content codes. Different product types trigger different storage rule applications, allowing the system to maintain safety compliance while adapting storage strategies to various scenarios such as high-value items, hazardous materials, or frequently accessed products.
3Productivity
If the WMS handles detailed storage location control, then centralization is achieved, but performance penalties occur due to computational burden
Solution Approach 1:
The control system is segmented into two functional layers: the WMS handles high-level warehouse management and container tracking, while the main controller handles detailed storage location determination and rule evaluation. This segmentation reduces the computational burden on the WMS, improving overall system performance while maintaining automated control through the specialized main controller.
4Ease of operation
If storage locations are selected without considering product types, then storage space utilization is maximized, but product accessibility and safety are reduced
Solution Approach 1:
The system applies different storage strategies to different product types based on their specific requirements. High-value or frequently accessed products are placed in more accessible locations, while bulk storage items can be placed in less accessible positions. This local quality approach ensures that each product type receives appropriate storage treatment, balancing accessibility needs with space utilization efficiency.
Data Source
AI summary
A method controls storage locations of products stored in storage containers in an automated storage and retrieval system operated by container handling vehicles. The storage and retrieval system comprises a grid structure with storage columns adapted for holding stacks of storage containers. The grid structure has a corresponding rail system above the storage columns for guiding movements of the vehicles adapted for transferring storage containers to and from the storage columns. Each vehicle comprises a vehicle controller connected to driving means for controlling movements of the vehicle along the rail system relative to movements of other vehicles. Controlling of container handling vehicles and storage locations of storage containers is handled by a main controller of the automated storage and retrieval system communicating with a Warehouse Management System configured to register each storage container to be stored and type of one or more products placed in the storage containers. The method for storing storage containers includes: a transferring step, a transmitting step, a reading step, and a selecting step. The transferring step transfers a set of storage rules from the Warehouse Management System to the main controller. The transmitting step transmits unique identification codes of the storage containers from the Warehouse Management System to the main controller, and corresponding content codes from a content code module to the main controller. The content codes are linked to storage rules that the main controller will apply for storing the storage containers at locations defined by the storage rules. The reading step reads the content codes in the main controller, and determines a storage location for the storage container according to the storage rule linked to the content code. The selecting step selects container handling vehicles for transferring the storage container, and for each selected container handling vehicle transmits instructions from the main controller to the vehicle controller to transfer the storage container to a storage location defined by the corresponding storage rule and updates a storage location database with the identification and storage location of the storage container.