Multi-Level Storage Grid With Transfer Rails for Port Congestion
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Solution Overview
Problem
Existing automated storage and retrieval systems face issues with congestion around pick-up and drop-off ports, inefficient handling of storage containers, and limited flexibility in transporting items to and from the system, particularly in large grids, which can be exacerbated by the need for additional infrastructure and long travel distances.
Innovation Solution
The system incorporates a transfer rail grid below the top rail grid, allowing transport vehicles to move in two perpendicular directions, with a carrier platform capable of handling packaging boxes or pallets, and connects to an unloading/loading assembly, enabling efficient transfer of items between a picking/stocking station and external locations, and facilitates interconnection with multiple storage grids or third-party systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single top rail grid is used for container handling, then the system structure is simple, but congestion occurs around pick-up and drop-off ports reducing productivity
Solution Approach 1:
The system divides the rail grid into two separate levels: a top rail grid for container handling and a transfer rail grid for item transport. This segmentation allows independent operation of container handling and item transport functions, eliminating congestion at ports by enabling simultaneous operations on different levels without interfering with each other.
Solution Approach 2:
The invention adds a vertical dimension by introducing a transfer rail grid at a lower level than the top rail grid. This multi-level arrangement allows transport vehicles to operate simultaneously with container handling vehicles, providing additional spatial capacity for item movement and preventing congestion at pick-up and drop-off ports.
2Adaptability or versatility
If additional infrastructure is added to handle item transport, then transport flexibility improves, but system complexity and cost increase
Solution Approach 1:
The transfer rail grid serves multiple functions: transporting items between picking/stocking stations and storage containers, moving packaging boxes to unloading/loading assemblies, and facilitating communication between different system components. This multi-functional design provides transport flexibility without requiring separate dedicated infrastructure for each function.
Solution Approach 2:
The transfer rail grid acts as an intermediary system between the top rail grid (container handling) and ground-level operations (picking, stocking, loading, unloading). This intermediate layer enables efficient item transport while maintaining clear separation between container handling and item movement operations.
3Speed
If transport vehicles operate on the top rail grid, then container access is efficient, but item transport between stations becomes congested
Solution Approach 1:
The system segments vehicle operations by function: container handling vehicles operate on the top rail grid for efficient container access, while transport vehicles operate on the lower transfer rail grid for item transport. This functional segmentation eliminates competition for rail space and allows both operations to proceed at optimal speeds simultaneously.
Solution Approach 2:
By moving item transport operations to a lower vertical level (transfer rail grid), the system creates independent pathways for different types of traffic. Transport vehicles can move items between stations without interfering with container handling vehicles on the top level, thereby maintaining high container retrieval speed while improving item transport throughput.
Data Source
AI summary
A storage system includes a storage grid structure having a top rail grid upon which container handling vehicles work to store and retrieve storage containers in and from storage columns beneath the top rail grid. The storage system includes multiple transfer rails forming a horizontal transfer rail grid arranged at a level below the top rail grid. At least one transport vehicle operates on the transfer rail grid. The storage system includes a picking/stocking station for picking/stocking items between a storage container and a packaging box, and an unloading/loading assembly for unloading/loading packaging boxes containing such items. The transport vehicle is arranged to move upon the transfer rail grid in two perpendicular directions and comprises a carrier platform. The transfer rail grid is arranged to allow access for the transport vehicle to transport one or more packaging boxes at a time between the picking/stocking station and the unloading/loading assembly.