Suspended Load Crane for Automated Warehouse
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Solution Overview
Problem
Traditional load cranes in automated warehouses are inefficient due to the need for floor-mounted rails or tracks, which occupy valuable space and require heavy stabilizing means, leading to increased material and energy costs, as well as complex installation processes.
Innovation Solution
A load crane design featuring a suspension unit that allows the crane to be suspended above floor level, eliminating the need for floor-mounted rails, combined with a lightweight structure and efficient belt drive unit for movement, enabling easier installation, reduced energy consumption, and increased speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional load cranes use floor-mounted rails or tracks, then the crane can be supported and guided, but valuable floor space is occupied and heavy stabilizing means are required
Solution Approach 1:
The load crane is suspended from the ceiling structure above floor level, transitioning the support system from the horizontal floor plane to the vertical ceiling plane. This dimensional change releases valuable floor space while the ceiling structure provides the necessary support and guidance for the crane's movement.
Solution Approach 2:
The support and guidance function is extracted from the floor-mounted rails and transferred to the ceiling structure. The ceiling takes over the role of providing structural support and movement guidance, eliminating the need for floor-mounted stabilizing means.
2Stability of the object's composition
If the load crane is made heavy with stabilizing means, then the crane is more stable, but material costs and energy consumption increase
Solution Approach 1:
The stabilizing function is extracted from the crane's own structure and transferred to the ceiling support system. The ceiling structure provides the stability and support that would otherwise require heavy stabilizing means on the crane itself, reducing the crane's weight and energy consumption.
Solution Approach 2:
Instead of making the entire crane heavy for stability, only the necessary minimal structure is provided on the crane itself, while the ceiling support system provides the excessive or additional stability support needed for safe operation.
3Ease of manufacture
If the load crane is delivered in one piece, then installation is straightforward, but an opening in the roof is required and installation is complex
Solution Approach 1:
The load crane is divided into multiple sections that can be delivered separately through existing openings and assembled on-site. This segmentation eliminates the need for large roof openings while maintaining installation feasibility through modular assembly.
Solution Approach 2:
The crane sections are pre-assembled and prepared outside the warehouse, with connections and components readied in advance. This preliminary preparation simplifies the on-site assembly process, allowing quick installation without requiring complex on-site manufacturing or large openings.
4Speed
If floor-mounted rails are used, then the crane can move along the aisle, but valuable space is lost and reconfiguration is difficult
Solution Approach 1:
The movement guidance is moved from the floor plane to the ceiling plane. The ceiling-mounted tracks or guides provide the necessary directional control for crane movement while leaving the floor space completely free for reconfiguration and intermediate storage.
Solution Approach 2:
The suspension system allows the crane to be easily repositioned or removed from the ceiling structure without permanent floor modifications. This dynamic configuration enables flexible adaptation of the warehouse layout for different storage and operational requirements.
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
The suspended load crane design optimizes space usage, reduces material costs, lowers energy consumption, and facilitates easier expansion or reconfiguration of the warehouse, while maintaining stability and efficiency in goods handling.
Implementation Method 1
the suspension unit comprises roller means configured to movably support the load crane against support beams arranged along a transport aisle of the automated warehouse
Implementation Method 2
efficient belt drive unit for movement
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A load crane (20) for use in an automated warehouse is provided. The warehouse has a plurality of rows which extend vertically in a plurality of levels, and are arranged in parallel in a horizontal direction to form a rack. The crane (20) comprises a pair of spaced apart vertical struts (13) and a goods support arrangement (32) connected to the vertical struts (13). The goods support arrangement comprises a number of levels (38) for intermediate storage of goods (14). The crane (20) further comprises an elevator unit (36) and a suspension unit (21) configured to suspend the load crane (20) above floor level in the automated warehouse. To be published with Fig. 2