Automated Warehouse Stack Retrieval with Dual Handling Devices
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Solution Overview
Problem
Existing storage systems face inefficiencies in accessing containers located in the middle or bottom of stacks due to the need for extensive 'digging' operations, which consume time and reduce productivity, especially when dealing with multi-product stacks where aisle space is limited and frequent access to various product lines is required.
Innovation Solution
The introduction of a first handling device capable of lifting multiple non-target containers and a second handling device designed to lift and move a target container separately, allowing for efficient retrieval of containers from any stack level by reducing the number of lifting operations required, thereby increasing speed and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If containers are stacked in rows to improve storage density, then storage density is improved, but access time to containers in the middle or bottom of stacks increases
Solution Approach 1:
The system segments the stack access operation into two independent parts: a first handling device that retrieves containers from the middle or bottom of stacks, and a second handling device that retrieves containers from the top of stacks. This segmentation allows parallel operations and eliminates the sequential dependency where top containers must be removed before accessing lower containers, thereby reducing access time while maintaining high storage density through vertical stacking.
2Device complexity
If a single handling device is used to retrieve containers from stacks, then device complexity is reduced, but productivity decreases due to extensive digging operations
Solution Approach 1:
The system divides the container retrieval function into two specialized handling devices: a first handling device for accessing middle and bottom containers, and a second handling device for accessing top containers. This functional segmentation enables simultaneous retrieval operations from different stack levels, significantly improving productivity without requiring overly complex single-device mechanisms.
Solution Approach 2:
The system introduces a vertical dimension to the handling device operations by positioning the first handling device at a lower level to access middle and bottom containers, while the second handling device operates at the top level. This multi-level arrangement enables parallel access to different vertical zones of the stacks, increasing retrieval speed while keeping individual device designs relatively simple.
3Ease of operation
If aisles are provided between rows of shelves to enable product access, then ease of operation is improved, but storage density deteriorates
Solution Approach 1:
The system replaces the traditional mechanical aisle-based access system with an automated robotic handling system. The first and second handling devices use automated lifting and transport mechanisms to retrieve containers from any position in the stacks without requiring physical aisle space. This substitution eliminates the need for aisles between stacks, maximizing storage density while maintaining ease of operation through automated control.
Data Source
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Figure 3~3(c)
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AI summary
A storage system suitable for storing multiple product lines in an automated warehouse environment is disclosed. The storage system comprises a frame containing a plurality of stacks (112) of containers (110), a first handling device (150) capable of lifting a plurality of containers (110a) from a stack (112) in a single operation, and a second handling device (30) capable of lifting a single container (110b) and moving the container (110b) laterally. The first and second handling devices (150, 30) are disposed above the frame and are independently moveable to access different stacks (112). The first and second handling devices (150, 30) can work together to remove a target container (110b) quickly and with minimum use of resources.