Multi-Storey Storage Shuttles for Automated Mixed Pallet Formation
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Solution Overview
Problem
Existing multi-storey goods storage arrangements face inefficiencies in automating the process of creating mixed pallets, relying on manual handling and limited automation in combining different items from various pallets for delivery.
Innovation Solution
An automated multi-storey goods storage system utilizing computer-controlled shuttles and conveyors, with suspended shuttles picking up items from selected pallets and placing them on a second pallet, supported by transfer carts and vision sensors for precise positioning, and powered by electric motors that generate power during braking, enabling fully automated pallet formation and dispatch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual picking is used to combine different objects from different pallets into mixed pallets, then flexibility in creating mixed pallets is maintained, but labor intensity and operational efficiency deteriorate
Solution Approach 1:
The automated picking system is segmented into independent functional modules: vision sensors for detection, robotic manipulators for picking, conveyor systems for transport, and control systems for coordination. Each module operates semi-independently, allowing the system to achieve high automation while maintaining manageable complexity through modular architecture.
Solution Approach 2:
The automated picking system is designed with universal components that can handle multiple types of objects and pallet configurations. The vision sensors can detect various object types, the robotic manipulators can grasp different shapes and sizes, and the conveyor system can accommodate different pallet dimensions, enabling a single system to perform multiple picking tasks without requiring separate specialized equipment for each case.
2Productivity
If automated shuttles and conveyors are used to transport pallets, then productivity and operational efficiency are improved, but energy consumption increases
Solution Approach 1:
The system converts the energy that would be wasted during shuttle braking into useful electrical energy through regenerative braking. The electric motors acting as generators during deceleration capture kinetic energy and feed it back to the power system, transforming what would be energy loss into energy recovery, thereby reducing overall energy consumption while maintaining high transport speeds.
Solution Approach 2:
The conveyor system and shuttles operate continuously without idle stops, maintaining constant motion to transport pallets and create mixed pallets. This continuous operation maximizes productivity by eliminating downtime between tasks, and when combined with regenerative braking during necessary decelerations, it optimizes energy utilization by ensuring motors are constantly performing useful work rather than idling.
3Manufacturing precision
If vision sensors and detectors are installed on shuttles for precise positioning, then manufacturing precision and positioning accuracy are improved, but device complexity and cost increase
Solution Approach 1:
The vision sensors, detectors, and positioning systems are merged into an integrated sensing package mounted on each shuttle. This consolidation combines multiple detection functions into a unified system that shares common hardware components and processing resources, achieving high positioning accuracy through sensor fusion while reducing overall system complexity compared to having separate independent systems for each function.
Solution Approach 2:
The vision sensors and detectors on the shuttles enable the system to automatically detect object positions, identify optimal picking locations, and adjust shuttle trajectories in real-time without human intervention. The system uses its own sensing capabilities to self-correct positioning errors and optimize pickup operations, achieving high precision through autonomous feedback control rather than relying on external manual positioning mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates efficient and automated creation of mixed pallets, improving storage and delivery processes by reducing manual intervention and enhancing operational efficiency through precise automation and power management.
Implementation Method 1
The electrical motors can be arranged to generate electrical power during braking of the shuttle
Data Source
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AI summary
A multi-storey goods storage arrangement comprising a plurality of levels of storage lines arranged in parallel and transport lines extending between opposing ends of said storage lines, wherein a transfer cart is operable along each transport line. It further comprises a top shuttle suspending from top rail arrangement on said transfer cart and moveable out from said transfer cart into a suspension rail arrangement in said storage lines, and lifting means arranged on said top shuttle to lift goods stored in said storage lines and to transport lifted goods to the transfer cart.