Two-Level Storage Grid Layout for Transfer Column Congestion
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Solution Overview
Problem
Existing automated storage and retrieval systems face congestion issues at transfer columns, limited flexibility in handling storage containers, and vulnerability to single-point failures, which hinder efficiency and require costly infrastructure expansions.
Innovation Solution
The system incorporates a storage grid structure with interconnected transfer columns and a transfer rail grid that allows container handling vehicles to move in two perpendicular directions, enabling flexible transfer of containers between storage columns and external locations, with dual-track rails facilitating multiple vehicle paths and reducing reliance on specific ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple container handling vehicles operate at transfer columns, then transfer capacity increases, but congestion at transfer columns increases and availability decreases
Solution Approach 1:
The system divides the transfer function into two distinct vehicle types: container handling vehicles (CHVs) that operate on the top rail grid, and container transfer vehicles (CTVs) that operate on the lower transfer rail grid. This segmentation allows simultaneous operation of multiple vehicles without congestion at transfer columns, as CTVs handle the actual container exchange while CHVs perform other tasks.
Solution Approach 2:
The invention introduces a vertical dimension to the transfer operation by using a two-level rail grid structure. The top rail grid operates at one elevation while the transfer rail grid operates at a lower elevation, allowing container transfer vehicles to approach transfer columns from below rather than competing for horizontal space at the same level as container handling vehicles.
2Device complexity
If traditional single-point transfer ports are used, then system structure is simpler, but the system becomes vulnerable to single-point failures and lacks flexibility
Solution Approach 1:
Transfer columns in the invention serve multiple functions: they act as vertical transfer ports between the top rail grid and lower transfer rail grid, and simultaneously serve as loading/unloading points for container transfer vehicles. This multi-functionality eliminates single-point failures by providing alternative operational modes and pathways.
Solution Approach 2:
The system employs dynamic vehicle routing where container transfer vehicles can be dispatched to different transfer columns based on real-time system conditions and container destinations. This dynamic allocation provides flexibility and redundancy, allowing the system to adapt to failures or varying operational demands.
3Device complexity
If container transfer vehicles operate on the same rail grid as container handling vehicles, then infrastructure is simpler, but vehicle congestion and operational conflicts occur
Solution Approach 1:
The rail infrastructure is segmented into two separate grids: the top rail grid dedicated to container handling vehicles and the transfer rail grid dedicated to container transfer vehicles. This physical segmentation eliminates operational conflicts and congestion by providing dedicated pathways for each vehicle type.
Solution Approach 2:
The system uses vertical separation with the transfer rail grid positioned at a lower elevation than the top rail grid. This dimensional separation allows both vehicle types to operate simultaneously without interference, maintaining infrastructure efficiency while avoiding congestion.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
The present invention provides a storage system (1) comprising a storage grid structure (104) and multiple container handling vehicles (200,300), the storage grid structure comprises vertical column profiles (102) defining multiple storage columns (105), in which storage containers (106) can be stored one on top of another in vertical stacks (107), and at least one transfer column (119,120), the column profiles are interconnected at their upper ends by top rails (110,111) forming a horizontal top rail grid (108) upon which the container handling vehicles (200,300) may move in two perpendicular directions, the container handling vehicles are able to retrieve storage containers (106) from, and store storage containers in, the storage columns (105), and transport the storage containers on the storage grid structure, wherein the storage grid structure (104) comprises at least one horizontal transfer section (2); and the storage system comprises multiple container transfer vehicles (6) and transfer rails (110',111') forming a transfer rail grid (5) upon which the container transfer vehicles (6) may move in at least one horizontal direction, and the transfer section (2) is arranged at a level below the top rail grid (108) and extends from an external side (12) of the storage grid structure (104) to a position below the at least one transfer column (119,120) and comprises at least a section of the transfer rail grid (5) upon which section the container transfer vehicles (6) may pass each other and move in two perpendicular horizontal directions; and each of the container transfer vehicles comprises a container carrier (38) for carrying a storage container (106) and a wheel arrangement (32a,32b) for moving the container transfer vehicle (6) in two perpendicular directions upon the transfer rail grid (5); and wherein the at least one transfer column (119,120) extends from the top rail grid (108) to the transfer section (2), such that a storage container (106) may be transferred between the top rail grid (108) and the container carrier of one of the container transfer vehicles (6).