Storage Grid Rearrangement for Edge Free-Space Imbalance
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Solution Overview
Problem
Existing automated storage and retrieval systems often experience uneven distribution of free spaces, leading to deep holes at the edges of the storage grid, which impede efficient operations by increasing travel distances for container handling vehicles.
Innovation Solution
A central computer system monitors the grid for uneven free space distribution and initiates rearranging jobs to distribute containers more evenly across the grid, prioritizing these jobs over regular operations to ensure sufficient free spaces are available for normal operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If containers are stored in stacks in storage columns, then storage capacity is improved, but free spaces become concentrated at edges creating deep holes that increase travel distances
Solution Approach 1:
The system proactively monitors free space distribution and initiates rearranging jobs before deep holes significantly impact operations. By detecting uneven distribution early and redistributing containers preemptively, the system prevents the formation of problematic deep holes that would force vehicles to travel excessive distances, thus maintaining operational efficiency while preserving storage capacity.
2Ease of operation
If containers are redistributed to eliminate deep holes, then travel distance is reduced, but system complexity increases due to monitoring and rearranging operations
Solution Approach 1:
The system employs automated monitoring through the central computer that continuously tracks free space distribution without human intervention. When uneven distribution is detected, the system automatically generates and executes rearranging jobs using existing container handling vehicles, eliminating the need for additional complex infrastructure while maintaining optimal free space distribution.
Solution Approach 2:
The central computer continuously monitors the distribution of free spaces and uses this feedback to determine when rearranging operations are necessary. This closed-loop control system adjusts container distribution based on real-time conditions, initiating rearranging jobs only when needed, thus balancing operational efficiency with system complexity by avoiding unnecessary operations.
3Ease of operation
If rearranging jobs are prioritized over regular operations, then free space distribution is improved, but productivity decreases due to interruption of normal operations
Solution Approach 1:
The system performs partial rearranging operations by transporting individual containers to edges to create free spaces, rather than进行全面 redistribution. This selective approach addresses the free space distribution problem with minimal disruption to ongoing operations, allowing regular storage and retrieval tasks to continue while gradually improving the distribution of free spaces across the grid.
Data Source
AI summary
A method and system for rearranging containers in a storage and retrieval system comprising a three-dimensional storage grid structure for storing items. The grid structure forms vertical storage columns each having a horizontal area defined by the size of an access opening of the vertical storage columns. The framework structure comprises a rail system arranged above the storage columns. The method comprises checking if there are free spaces along at least one of the edges of the grid of the storage and retrieval system, checking if there are enough free spaces in the non-edge cells of the grid of the storage and retrieval system to perform normal operations, and performing rearranging if there are free spaces along at least one of the edges of the grid of the storage and retrieval system and there is not enough free spaces in the non-edge cells of the grid of the storage and retrieval system to perform normal operations.