Storage systems and methods
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Solution Overview
Problem
Existing storage systems with stacked containers in rows face limitations in accommodating varying product heights and lack integrated services for condition monitoring, control, and safety within enclosed spaces, leading to inefficiencies and increased costs.
Innovation Solution
A storage system featuring a grid framework with uprights and horizontal rails that supports robotic load handling devices and integrates service means for power, data communication, sensing, and fluid supply, enabling condition monitoring, control, and safety features within the framework, allowing for flexible container access and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If free-standing stacks of containers are arranged in rows to reduce storage volume, then storage density is improved, but access to specific containers requires complicated hoisting mechanisms increasing system complexity
Solution Approach 1:
The patent replaces traditional mechanical hoisting mechanisms with a robotic load handler that uses a rectangular tube to grip and lift containers. The robotic system can be positioned at different locations along the stack and retrieve containers of varying heights without requiring complex overhead hoisting infrastructure, thus reducing storage volume while maintaining access simplicity.
2Ease of operation
If a rectangular tube load handler is used to extract containers from any level in the stack, then container accessibility is improved, but the tube height must accommodate the largest stack restricting maximum stack height
Solution Approach 1:
The patent employs a robotic load handler with adjustable positioning capabilities that can dynamically adapt to different stack heights and container positions. The robotic system can move along tracks positioned at optimal heights and use extendable or adjustable gripping mechanisms to access containers at any level without requiring the entire tube structure to be as tall as the maximum stack, thereby maintaining accessibility while allowing greater stack heights.
3Productivity
If stacks of containers are arranged within a frame structure with robotic load handlers on tracks, then container management is improved, but the system requires extensive infrastructure increasing device complexity
Solution Approach 1:
The patent integrates multiple functions into the robotic load handler system, combining container gripping, lifting, positioning, and transport capabilities in a single robotic unit. The rectangular tube design serves both as the gripping mechanism and as part of the positioning system, reducing the need for separate infrastructure components while maintaining improved container management efficiency.
4Volume of moving object
If storage bins are arranged in dense stacks to maximize space utilization, then storage density is improved, but monitoring and control of bin contents becomes difficult
Solution Approach 1:
The patent introduces sensors and monitoring devices as intermediary elements between the robotic load handler and the container contents. These sensors can detect container positions, identify products within containers, and provide feedback to the control system, enabling monitoring and control of densely stacked containers without requiring physical access to each container, thus maintaining high storage density while improving detectability.
Data Source
AI summary
A storage system is disclosed where goods can be stored in containers and the containers are stored in stacks. Above the stacks runs a grid network of rails (e.g., tracks) on which load handling devices can run. To take containers from the stacks and deposit then at alternative locations in the stacks or deposit then at stations where goods may be picked. The framework may be provided with one or more of the following exemplary services: power, power control, heating, lighting, cooling, sensors, and data logging devices. The provision of these services within the framework rather than across the system as a whole, can allow for flexibility in storage whilst reducing cost and inefficiency.