3D Warehouse Shuttle and Car Coordination for Space Optimization
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Solution Overview
Problem
Conventional warehouse systems, such as channel storage systems, inefficiently use space due to the need for lanes for stacker cranes, and do not allow direct access to storage spaces within channels, limiting the ability to retrieve goods from any desired location.
Innovation Solution
A three-dimensional warehouse system with lanes and rows, where cars are movable in the transverse direction and shuttles in the longitudinal direction, allowing for direct access to storage spaces through a control system that clears paths and utilizes a shuttle to retrieve goods from any storage space, optimizing space usage and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stacker cranes are used to supply racks with goods, then goods can be stored and retrieved, but space is lost for lanes between rack fronts
Solution Approach 1:
The patent transitions from a two-dimensional rack front access system to a three-dimensional system by introducing vertical lanes and multi-level storage. Shuttles operate in the vertical dimension along lanes, while cars move goods horizontally between lanes, eliminating the need for horizontal access lanes and maximizing warehouse space utilization.
Solution Approach 2:
The system divides the warehouse into discrete lanes, rows, and levels, with independent shuttles and cars operating in each segment. This segmentation allows simultaneous operations in different zones without blocking access lanes, as each lane can be independently accessed by its own shuttle.
2Area of stationary object
If channel storage systems are used, then space usage is improved, but direct access to storage spaces within channels is not possible
Solution Approach 1:
Each storage space in the patent has distinct local qualities: it can be independently accessed by a shuttle from its lane, while also being part of a larger row accessible by cars. This localized access capability allows direct retrieval from any storage space without requiring FIFO/LIFO channel operations.
Solution Approach 2:
The patent introduces cars as intermediary vehicles that transfer goods between lanes and rows. When goods need to be accessed from a different lane than where the shuttle is positioned, the car acts as a mediator to transport the goods to the appropriate location, enabling flexible access patterns.
3Area of stationary object
If multiple cars are arranged in each row to maximize storage, then space efficiency increases, but path clearing becomes more complex for shuttle access
Solution Approach 1:
The control system performs preliminary actions by proactively clearing paths before shuttles need to access storage spaces. When a retrieval operation is initiated, the system automatically moves cars out of the way and positions them in holding areas, so that shuttles can operate without delays or complex coordination during actual goods retrieval.
Solution Approach 2:
The system dynamically adjusts car positions based on operational needs. Cars can be moved to holding positions when path clearing is needed, and returned to storage positions when not needed. This dynamic repositioning allows the system to maintain high storage density while enabling smooth shuttle operations when required.
Data Source
AI summary
The present disclosure relates to a warehouse system (100) comprising a three-dimensional arrangement of storage spaces including a plurality of lanes extending in a longitudinal direction (X), a plurality of rows extending in a transverse direction (Z), and one or more levels in a vertical direction (Y). One or more cars (104) for carrying goods (106) are arranged in at least one of the plurality of rows, wherein the one or more cars (104) in a respective row are drivable along the respective row in the transverse direction (Z), and wherein the number of the one or more cars (104) in the respective row is less than the number of the plurality of lanes. The warehouse system (108) comprises at least one shuttle (108) drivable to shift goods (106) along at least one of the plurality of lanes in the longitudinal direction (X).