Multi-Level Warehouse Storage Layout for Shorter Retrieval Paths
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Solution Overview
Problem
Existing warehouse storage structures face challenges with excessively long travel paths and aisles, leading to increased travel times and reduced throughput due to the need to balance storage capacity and aisle length, which can be prohibitive in terms of space and efficiency.
Innovation Solution
A storage and retrieval system utilizing multilevel vertical conveyors and autonomous transport robots (bots) that facilitate direct transfer of case units between storage aisles and conveyors, optimizing travel paths and reducing travel distances through modular and scalable design elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the storage aisles are made longer to increase storage capacity, then more goods can be stored, but the travel time and transport time increase excessively
Solution Approach 1:
The patent transitions from a traditional single-level horizontal storage layout to a multi-level vertical storage structure with transfer decks at different heights. This dimensional change allows the system to increase storage capacity vertically rather than horizontally, thereby reducing the length of travel paths while maintaining or increasing storage capacity. The transfer decks connect multiple storage levels, enabling efficient vertical and horizontal movement of items.
2Speed
If the number of storage aisles is increased to reduce aisle length, then individual aisle travel time decreases, but the total travel path length increases
Solution Approach 1:
The storage system is divided into multiple independent storage levels, each accessible via transfer decks. This segmentation allows the system to break down the total travel path into smaller, manageable segments at different vertical levels. Instead of traversing one extremely long horizontal path, the system distributes storage across multiple shorter paths at different heights, reducing the maximum travel distance required to access any given item.
Solution Approach 2:
By adding vertical dimensions through multiple storage levels and transfer decks, the system creates a three-dimensional storage architecture. This allows items to be accessed via vertical transfers between levels combined with shorter horizontal movements, rather than requiring traversal of extremely long horizontal aisles. The combination of vertical and horizontal movement paths optimizes overall travel efficiency.
3Area of stationary object
If the building footprint is reduced to decrease travel distances, then space utilization improves, but storage capacity may be compromised
Solution Approach 1:
The patent充分利用 vertical space by implementing multiple storage levels stacked vertically, connected by transfer decks. This vertical expansion allows the system to dramatically increase storage capacity within the same building footprint. Instead of expanding horizontally, the system grows upward, maintaining a compact footprint while accommodating large quantities of stored items through multi-level storage configurations.
Solution Approach 2:
The storage system employs a nested structure where multiple storage levels are stacked one above another, with transfer decks integrating connections between levels. This nesting arrangement maximizes the use of vertical space within the building footprint, allowing compact packaging of storage capacity. Each level is nested within the vertical envelope of the building, efficiently utilizing available space without requiring horizontal expansion.
Data Source
AI summary
A storage and retrieval system is provided and includes a transfer deck having a longitudinal axis, a first storage section and a second storage section. The first storage section and second storage section are located on opposite sides of the transfer deck and are substantially symmetrically opposed to one another about the longitudinal axis, where each of the first and second storage sections includes storage aisles that are in communication with the transfer deck.