Track Shutdown Zoning for Malfunctioning ASRS Vehicles
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Solution Overview
Problem
Existing automated storage and retrieval systems face challenges in accessing the transport rail system for inspection or maintenance of malfunctioning vehicles, requiring a complete shutdown which is costly and risky for large systems with many vehicles in operation.
Innovation Solution
A method and control system that allows personnel to safely access the track system by wirelessly detecting anomalies, setting up a shutdown zone, rerouting vehicles, and creating a physical barrier to enable maintenance without a complete shutdown, using wireless communication and remotely operated vehicles to manage vehicle movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire system is shut down to access the transport rail system for maintenance or inspection, then personnel safety is ensured, but system productivity is completely lost
Solution Approach 1:
The system is divided into operational zones: a shutdown zone where maintenance is performed and a continuing operation zone where other vehicles remain active. This spatial segmentation allows simultaneous maintenance activities and system operations without mutual interference
Solution Approach 2:
A control system acts as an intermediary to coordinate between maintenance activities and ongoing operations. The control system manages vehicle routing, sets up virtual fences, and coordinates the timing of maintenance operations with system traffic flow
2Reliability
If the entire system is shut down for maintenance, then maintenance can be performed without risk, but operational costs increase due to complete system downtime
Solution Approach 1:
The rail system is segmented into maintenance areas and operational areas, allowing maintenance to be performed on specific vehicles or track sections while other parts continue generating revenue
Solution Approach 2:
The system maintains continuous useful action by keeping most vehicles operational while only taking specific vehicles offline for maintenance. The virtual fence technology enables this partial shutdown without affecting overall system productivity
3Ease of repair
If the entire system is shut down to access malfunctioning vehicles, then proper maintenance can be performed, but the time required for system recovery increases
Solution Approach 1:
The control system performs preliminary actions by automatically routing other vehicles away from the maintenance area and setting up virtual fences before maintenance begins. This preparation is done automatically and quickly, reducing the time vehicles are out of service
Solution Approach 2:
The system performs self-service through automated vehicle routing and positioning. When a vehicle needs maintenance, the control system automatically maneuvers other vehicles to create access space without requiring complete system shutdown or manual intervention
Data Source
Figure 1
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Figure 4A~4B
AI summary
A method for handling malfunctioning vehicles (240,340) on a track system (108,308) constituting part of a storage and retrieval system (1), the track system (108,308) forming a grid pattern of adjacent cells, wherein the storage and retrieval system (1) comprises - a plurality of remotely operated vehicles (230,330,240,340,250,350) configured to move laterally on the track system, wherein each of the plurality of remotely operated vehicles comprises driving wheels, and - a control system (500) for monitoring and controlling wirelessly movements of the plurality of remotely operated vehicles, wherein 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, setting up a two-dimensional shutdown zone (225) on the track system comprising a malfunctioning vehicle zone (225a) including the halt position of the malfunctioning vehicle and an entrance zone (225b) for entry into the malfunctioning vehicle zone, the entrance zone ( extending between the malfunctioning vehicle zone and a location at a periphery of the track system, 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 zonefor an external operator by at least one of unlocking a gateway at the periphery, 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.