Track Grid Shutdown Zones for Malfunctioning Vehicle Access
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Solution Overview
Problem
Existing automated storage and retrieval systems face challenges in allowing personnel to access the track system for inspection or maintenance of malfunctioning container handling vehicles without requiring a complete shutdown, which is costly and undesirable, especially in large systems.
Innovation Solution
A method is implemented that allows personnel to safely enter the track system to handle malfunctioning vehicles by creating a shutdown zone using wireless communication with the control system, which registers anomalies, sets up a two-dimensional shutdown zone, and orders remotely operated vehicles to halt or move out of the zone, ensuring safety for human operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire track system is shut down to allow personnel access for maintenance or inspection of malfunctioning vehicles, then safety of personnel is ensured, but system productivity and operational efficiency deteriorate due to complete system halt
Solution Approach 1:
The track system is divided into multiple independent zones, allowing selective shutdown of only the specific zone containing the malfunctioning vehicle while other zones continue operating. This spatial segmentation enables personnel safety in the shutdown zone without halting the entire system.
Solution Approach 2:
Different operational states are applied to different parts of the system: the malfunctioning zone is shut down for safety while other zones maintain normal operation. This local differentiation resolves the contradiction by applying safety measures only where needed rather than system-wide.
2Ease of repair
If the entire track system is shut down to handle malfunctioning vehicles, then ease of repair and maintenance is improved, but operational costs worsen due to loss of system-wide productivity
Solution Approach 1:
The system is segmented into maintainable zones, allowing maintenance activities to be performed in isolated sections without affecting other operational sections. This enables ease of repair while minimizing the scope of shutdown and associated operational losses.
Solution Approach 2:
The system proactively creates shutdown zones and redirects vehicles before maintenance is needed, allowing seamless transition to maintenance mode in specific areas without disrupting overall system flow. This preliminary organization reduces the impact of maintenance activities on operational costs.
3Reliability
If a complete system shutdown is implemented for vehicle maintenance, then safety of personnel is ensured, but loss of time worsens due to system-wide halt
Solution Approach 1:
The track system is divided into independent operational segments, allowing maintenance to be performed in one segment while other segments continue operating. This spatial segmentation minimizes system downtime by isolating the shutdown area to only what is necessary for safety.
Solution Approach 2:
Instead of shutting down the entire system, only the minimal necessary portion (the shutdown zone containing the malfunctioning vehicle) is halted. This partial action approach maintains safety while preserving maximum operational time in the remaining active zones.
4Productivity
If the track system continues operating while personnel access malfunctioning vehicles, then productivity is maintained, but safety of personnel deteriorates due to potential vehicle movement
Solution Approach 1:
The system creates a spatially separated shutdown zone that isolates personnel from moving vehicles while allowing other zones to continue operation. This segmentation physically protects personnel without requiring complete system shutdown.
Solution Approach 2:
The shutdown zone acts as an intermediary safety barrier between personnel and the rest of the operating system. This intermediate zone enables personnel access to malfunctioning vehicles while maintaining a clear separation from active vehicle traffic.
Data Source
AI summary
A method handles malfunctioning vehicles on a track system constituting part of a storage and retrieval system configured to store a plurality of stacks of storage containers. The track system forms a grid pattern of adjacent cells. The storage and retrieval system includes a plurality of remotely operated vehicles configured to move laterally on the track system, wherein each of the plurality of remotely operated vehicles comprises driving wheels, and a control system for monitoring and controlling wirelessly movements of the plurality of remotely operated vehicles. The control system performs at least the following steps by wireless data communication: detecting an anomaly in an operational condition of a vehicle on the track system, registering the vehicle with the anomalous operational condition as a malfunctioning vehicle, registering a halt position of the malfunctioning vehicle relative to the supporting track system, and setting up a two-dimensional shutdown zone on the track system. The setting up a two-dimensional shutdown zone on the track system includes a malfunctioning vehicle zone including the halt position of the malfunctioning vehicle, and an entrance zone for entry into the malfunctioning vehicle zone. The entrance zone extends between the malfunctioning vehicle zone and a location at a periphery of the track system. The control system further performs ordering the remotely operated vehicles in operation within the shutdown zone to either move out of the shutdown zone, a halt or a combination thereof, and indicating allowance of entry into the entrance zone for an external operator by at least one of: unlocking a gateway at the periphery, and producing an entry-allowed signal registrable by a human operator located at the periphery such that the human operator may enter the entrance zone through the gateway.