Automated Warehouse Elevator Platform Parallel Cycles
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Solution Overview
Problem
The existing three-dimensional automated warehouse systems face inefficiencies due to a single cycle receiving-shipping sequence, leading to unnecessary elevator platform movement when empty, and imbalance in receiving and shipping capacities, which complicates capacity improvement and increases costs when equipment is out of order.
Innovation Solution
The system introduces dual layered stacked racks with alternating conveyor directions between shipping and receiving stations, allowing for simultaneous operation of stand-by conveyors and double-decker elevator platforms that can carry multiple packages, enabling efficient package transfer and balancing shipping and receiving operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cycle receiving-shipping sequence is used, then the system structure is simple, but the elevator platform must move empty between receiving and shipping, reducing efficiency
Solution Approach 1:
The system divides the elevator operation into two independent parallel cycles: one dedicated to receiving operations and another to shipping operations. This segmentation allows each elevator to specialize in one function, eliminating the need for empty return trips between different operational modes and improving overall productivity.
Solution Approach 2:
The patent combines receiving and shipping operations by implementing dual elevators that work simultaneously and independently. Both elevators operate in parallel, with one handling receiving while the other handles shipping, effectively merging the functionality into a coordinated dual-system approach that eliminates idle movement.
2Ease of operation
If receiving and shipping stations are separated, then operational independence is improved, but capacity imbalance occurs when one station is out of order
Solution Approach 1:
Each elevator is designed with multi-functionality, capable of performing both receiving and shipping operations. The control system can dynamically assign either elevator to either function based on real-time operational needs, ensuring that if one elevator or station is out of order, the other can compensate and maintain balanced capacity.
Solution Approach 2:
The system implements dynamic operational flexibility where elevators can switch between receiving and shipping functions based on real-time conditions. This dynamic allocation allows the system to adapt to failures or imbalances, maintaining reliability and capacity balance even when one station is out of order.
3Device complexity
If one-way routes are used for receiving and shipping, then the system design is simplified, but the receiving-shipping sequence becomes a single cycle reducing throughput
Solution Approach 1:
The patent implements continuous useful action by establishing two independent parallel cycles: one continuous receiving cycle and one continuous shipping cycle. Each elevator operates continuously in its designated cycle without interruption or idle return trips, maximizing throughput while maintaining simplified one-way route designs for each individual cycle.
Data Source
AI summary
An automated warehouse includes first and second stacked racks parallel to each other; first and second shipping-and-receiving stations placed at the same end of the stacked racks; transfer shuttles located between the stacked racks and between the shipping-and-receiving stations; elevator mechanisms equipped with first and second elevator platforms for receiving or transferring the packages to stand-by conveyors; and means for transferring the packages to and from the first and the second elevator platforms. The direction of motion of the stand-by conveyor of the first shipping-and-receiving station and the direction of the motion of the stand-by conveyor of the second shipping-and-receiving station, on the same level of stack, may be opposite; and the direction of motion of some of the stand-by conveyors pertaining to the first shipping-and-receiving station may be opposite to that of the rest of the stand-by conveyors of the first shipping-and-receiving station.