Removable Tub-on-Tray Assembly for Uniform Rack Handling
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Solution Overview
Problem
Automated storage and retrieval systems face challenges in uniformly handling and storing both trays with and without containers, as existing solutions require rigid containers to support themselves on spaced-apart rails, leading to inefficiencies and increased costs due to the need for reinforcement.
Innovation Solution
A tray and tub assembly where the tub is removably secured to the tray, allowing for uniform handling and storage, with the tray providing sufficient support, enabling the tub to be non-rigid and potentially thermoformed, reducing the need for reinforcement and facilitating cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid containers are used to support themselves on spaced-apart rails, then structural strength is improved, but manufacturing complexity and cost increase due to reinforcement requirements
Solution Approach 1:
The tray acts as an intermediary component between the rails and the container. The tray provides the rigid structural support needed to bear loads on the spaced-apart rails, while the container itself can be non-rigid and thermoformed. This mediator approach allows the container to be simpler to manufacture while the tray handles the structural requirements.
Solution Approach 2:
The system is divided into separate functional components: the tray provides structural support and interfaces with the rails, while the container provides storage functionality. This segmentation allows each component to be optimized independently - the tray for strength and the container for ease of manufacture.
2Strength
If rigid containers with reinforcement ribs are used, then load-bearing capacity is improved, but production cost and weight increase
Solution Approach 1:
The tray serves as the load-bearing intermediary that transfers forces between the rails and the container contents. The container itself needs only to contain items, not support its own weight on the rails, allowing it to be lighter and without reinforcement ribs.
3Ease of operation
If uniform handling of trays with and without containers is required, then operational efficiency is improved, but design flexibility is reduced
Solution Approach 1:
The tray is designed as a universal component that functions whether or not a container is attached. It can be handled by automated equipment in the same way regardless of container presence. The container is a separate optional element that attaches to the standardized tray, maintaining handling uniformity while allowing flexibility in whether containers are used.
Data Source
AI summary
A storage system includes a tray that can be stored on automated storage and retrieval racks. A tub is removably securable to the tray. The tub includes a bottom wall, a pair of opposed side walls and a pair of opposed end walls. The bottom wall of the tub is removably secured to the tray. Thus, some of the trays in the storage system can be provided with tubs for the storage of loose items.