Transfer Rail Grid Layout for Congestion-Free Storage Handling
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Solution Overview
Problem
Existing automated storage and retrieval systems face issues such as congestion at transfer columns, inefficiency due to separate drop-off and pick-up ports, vulnerability to single-point failures, and limited flexibility in handling storage containers, which impede system performance and require costly infrastructure expansions.
Innovation Solution
The system incorporates a transfer rail grid below the top rail grid, allowing container transfer vehicles to move in two perpendicular directions, with dual-track rails enabling vehicles to pass each other, and connects multiple storage grid structures, facilitating flexible and efficient transfer of storage containers without the need for additional ports or extensive conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional automated storage and retrieval system uses separate drop-off and pick-up ports at the periphery, then storage containers can be transferred in and out, but congestion occurs at transfer columns and system efficiency decreases
Solution Approach 1:
The patent introduces a transfer section located below the storage grid structure, creating a new dimensional space for container transfers. This underground transfer rail grid allows multiple container transfer vehicles to operate simultaneously in two perpendicular directions, eliminating the congestion that occurs at peripheral transfer columns and enabling continuous in-and-out operations without interference.
2Productivity
If additional ports or conveyor systems are added to handle increased storage container traffic, then transfer capacity increases, but infrastructure complexity and cost increase
Solution Approach 1:
The transfer section serves multiple functions: it acts as a transfer area for storage containers, provides passing lanes for container transfer vehicles, and enables simultaneous in-and-out operations. The dual-directional rail grid allows vehicles to travel in two perpendicular directions, providing versatile routing options without requiring additional peripheral ports or complex conveyor systems.
Solution Approach 2:
By moving the transfer operations to a lower dimension (below the storage grid), the system accommodates increased traffic capacity without expanding the horizontal footprint or adding complex peripheral infrastructure. The underground transfer rail grid provides multiple pathways for vehicles to pass each other and access transfer columns efficiently.
3Device complexity
If the system uses a single transfer column for both drop-off and pick-up operations, then infrastructure is simplified, but the system becomes vulnerable to single-point failures
Solution Approach 1:
The transfer section is segmented into multiple transfer columns that can be accessed independently by container transfer vehicles. Each transfer column serves as a separate access point to the storage grid, so if one transfer column or vehicle experiences a failure, other transfer columns can continue operations without interruption.
4Ease of operation
If container transfer vehicles operate on the top rail grid, then they can access storage columns directly, but they block each other and reduce transfer column availability
Solution Approach 1:
The patent relocates container transfer vehicle operations to a lower dimension by implementing the transfer rail grid below the storage grid structure. This allows vehicles to access transfer columns from below without blocking the top rail grid, maintaining direct access to storage columns while eliminating vehicle-to-vehicle blocking and improving transfer column availability.
Data Source
AI summary
A storage network includes a plurality of storage systems. Each storage system includes a storage grid structure, having at least one transfer column and a horizontal top rail grid upon which the container handling vehicle moves in two perpendicular directions, and at least one container handling vehicle. The storage system includes at least one container transfer vehicle and transfer rails forming a transfer rail grid upon which the container transfer vehicle moves in at least one horizontal direction. The container transfer vehicle includes a container carrier for carrying a storage container and a wheel arrangement for moving the container transfer vehicle in two perpendicular directions upon the transfer rail grid. The at least one transfer column extends from the top rail grid to the transfer section, such that a storage container may be transferred between the top rail grid and the container carrier of the container transfer vehicle.