Storage Grid Transfer Floor Layout to Reduce Column Congestion
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Solution Overview
Problem
Existing automated storage and retrieval systems face congestion issues at transfer columns, limited flexibility in handling storage containers, and are vulnerable to single-point failures, leading to inefficiencies and increased costs due to the need for additional infrastructure and long travel distances for container handling vehicles.
Innovation Solution
The system incorporates a storage grid structure with interconnected vertical column profiles and top rails, along with a horizontal transfer section that extends from the external side of the grid to below the transfer columns, allowing container transfer vehicles to move horizontally and transfer containers between the top rail grid and the transfer vehicles, reducing congestion and enabling flexible operation by minimizing the distance traveled by handling vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If container handling vehicles operate on the top rail grid to transfer storage containers, then storage containers can be retrieved and stored in vertical stacks, but congestion occurs at transfer columns and travel distances become long
Solution Approach 1:
The patent introduces a horizontal transfer section that extends from the external side of the storage grid to below the transfer columns, creating a new spatial dimension for container transfer operations. This allows container transfer vehicles to operate at a lower level rather than solely on the top rail grid, effectively adding a vertical dimension to the transfer path and reducing congestion at traditional transfer column locations.
Solution Approach 2:
The horizontal transfer section acts as an intermediary structure between the external side of the storage grid and the transfer columns. It provides a dedicated transfer floor and support structures that facilitate container movement without requiring vehicles to traverse the entire top rail grid distance, thus reducing travel time and improving transfer efficiency.
2Productivity
If additional infrastructure is added to handle container transfers, then transfer capacity increases, but system complexity and costs increase
Solution Approach 1:
The horizontal transfer section is designed to serve multiple functions: it provides a transfer floor for container movement, supports the transfer column structure, and creates additional access points to storage containers. This multi-functional design increases transfer capacity without requiring separate dedicated infrastructure for each function, thereby controlling system complexity.
Solution Approach 2:
The transfer system is segmented into distinct functional zones: the horizontal transfer section with its transfer floor, the transfer columns, and the top rail grid. This segmentation allows each component to be optimized independently and facilitates easier maintenance and operation, reducing overall system complexity while maintaining high availability.
3Ease of operation
If transfer columns are positioned at the periphery of the storage grid, then container access is simplified, but travel distances for vehicles increase
Solution Approach 1:
By extending the transfer section horizontally from the external side to below the transfer columns, the system creates a new access dimension. Vehicles can access containers through this horizontal transfer section at a reduced distance compared to traveling across the top rail grid to peripheral transfer columns, effectively shortening the movement path while maintaining easy access.
Data Source
AI summary
The present invention provides a storage system (1) comprising a storage grid structure (104) and multiple container handling vehicles (200,300), the storage grid structure comprises vertical column profiles (102) defining multiple storage columns (105), in which storage containers (106) can be stored one on top of another in vertical stacks (107), and at least one transfer column (119,120), the column profiles are interconnected at their upper ends by top rails (110,111) forming a horizontal top rail grid (108) upon which the container handling vehicles (200,300) may move in two perpendicular directions, the container handling vehicles are able to retrieve storage containers (106) from, and store storage containers in, the storage columns (105), and transport the storage containers on the storage grid structure, wherein the storage grid structure (104) comprises at least one horizontal transfer section (2); and the storage system comprises multiple container transfer vehicles (6) and a transfer floor (5) on which the container transfer vehicles (6) may move horizontally, and the transfer section (2) is arranged at a level below the top rail grid (108) and extends from an external side (12) of the storage grid structure (104) to a position below the at least one transfer column (119,120) and comprises at least a section of the transfer floor (5); and each of the container transfer vehicles comprises a container carrier (38) for carrying a storage container (106) and a wheel arrangement (32a,32b) for moving the container transfer vehicle (6) in at least two perpendicular directions on the transfer floor (5); and wherein the at least one transfer column (119,120) extends from the top rail grid (108) to the transfer section (2), such that a storage container (106) may be transferred between the top rail grid (108) and the container carrier of one of the container transfer vehicles (6).