Vertical Lift Conveyor Transfer for Faster Multi-Level Rack Handling
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Solution Overview
Problem
Existing shuttle storage systems face limitations in vertical lift throughput due to high acceleration and deceleration, which compromise system reliability, stability, and increase energy consumption, while also being limited by items losing contact during downward movement.
Innovation Solution
A storage system with a multi-level storage rack and vertical lift, utilizing a conveyor platform and rack conveyors controlled by a sensor and controller to initiate load transfer before exact alignment, allowing the lift conveyor platform to overtravel slightly beyond the rack level for early transfer initiation, thus minimizing settling time and preventing collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If automated storage systems use traditional horizontal layouts, then material handling is simplified, but floor space consumption increases and vertical utilization is poor
Solution Approach 1:
The patent transitions from traditional horizontal storage layouts to a vertical three-dimensional storage architecture. Multiple storage levels are stacked vertically with automated lift mechanisms operating between them, converting floor space consumption into vertical space utilization. This dimensional transformation dramatically reduces the footprint while maintaining storage capacity.
Solution Approach 2:
The storage system is divided into multiple independent storage levels (first storage level, second storage level, etc.) that can be accessed and operated independently. Each level functions as a separate module with its own storage racks and can be serviced by individual lift mechanisms, enabling modular expansion and maintenance.
2Area of stationary object
If multiple storage levels are stacked vertically, then floor space is reduced, but access to upper levels becomes difficult and slow
Solution Approach 1:
Automated lift mechanisms serve as intermediary devices between different storage levels. These lifts automatically transport materials between the first storage level, second storage level, and ground level without human intervention, eliminating the time loss associated with manual material handling across vertical distances.
Solution Approach 2:
The patent replaces manual mechanical material handling with automated electromechanical lift systems. The automated lifts use motorized mechanisms to vertically transport materials between storage levels, substituting slow manual operations with fast automated mechanical systems.
3Productivity
If automated lifts operate continuously, then productivity increases, but energy consumption and heat generation increase
Solution Approach 1:
The automated lift system operates on a periodic schedule rather than continuous operation. Lifts are activated only when materials need to be transported between storage levels, entering standby mode during idle periods. This periodic operation maintains productivity while significantly reducing energy consumption during non-operational times.
Solution Approach 2:
The control system automatically monitors and manages lift operations based on storage needs, activating lifts only when necessary without requiring continuous human supervision or energy input. The system self-regulates operation timing and intensity to optimize energy efficiency while maintaining productivity.
Data Source
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AI summary
Storage system with a multi-level storage rack, a vertical lift connecting the levels of the multi-level storage rack, the vertical lift having a conveyor platform, at least one rack level has a conveyor adjacent to the vertical lift, and a controller configured for controlling the lift, conveyor platform and conveyor such that the lift conveyor platform or conveyor are controlled to transfer a load between the lift conveyor platform and the rack conveyor or vice versa, wherein the transfer is controlled to be performed as soon as the lift conveyor platform and the rack conveyor are at same height and lifting platform over travels beyond transition level allowing the transfer to be initiated earlier by transferring the load from the higher lift conveyor platform to the lower rack conveyor or vice versa.