Optimal dwell point policies for automated storage/retrieval systems with dedicated storage

This study is to develop an optimal dwell point policy for automated storage/retrieval systems. For square-in-time racks with dedicated storage, we determine the optimal dwell points in closed form. We also confirm the intuitive remit that the input point is a good alternative dwell point for dedicated storage.     

Routing problem under the shared storage policy for unit-load automated storage and retrieval systems with separate input and output points

In this study the routing problem for unit-load automated storage and retrieval systems (AS/RSs) with separate input and output points is considered under the shared storage policy. The problem is to find an optimal travel route of a S/R (storage and retrieval) machine to process given storage and retrieval requests so that the total travel time is minimised, where the input and output points are possibly separate and the shared storage policy is assumed. We first give two types of formulations as 0–1 integer linear programming problems corresponding to two types of dwell point settings: the dwell point is the input point and the output point. Next, we propose a simple but efficient exact solution algorithm based on the formulations that utilises a general MILP (Mixed Integer Linear Programming) solver. Its efficiency is then demonstrated by numerical experiments. Instances with 400 items (200 for each storage and retrieval) are solved within 100 s.     

Relative pre-positioning of storage/retrieval machines in automated storage/retrieval system to minimize expected system response time

This paper is focused on the control problem of determining the dwell point of an idle storage/retrieval (S/R) machine in an automated S/R system to improve the overall system service level as measured by the turnaround time of requests to the system. The emphasis of the paper is on the minimization of the expected response time over all retrieval and storage requests executed by the system. The model presented is developed under the operating condition that each machine serves several dedicated aisles of the system. The aisles are assumed to exist in the same region of the automated storage/retrieval system (AS/RS) and thus form a valid order S/R zone. A solution algorithm for determining the optimal dwell point location is developed. The paper assumes a dynamic environment where orders arrive over time and are to be serviced by the S/R machine. A dwell point or strategic point to pre-position the machine is to be determined whenever the machine becomes idle in anticipation of an incoming service request. A numerical example is provided to demonstrate how the technique can be used in an actual production setting to improve the overall order turnaround time.     

Relative pre-positioning of storage/retrieval machines in automated storage/retrieval systems to minimize maximum system response time

In this paper, the problem of pre-positioning a storage/retrieval (S/R) machine in an automated storage/retrieval system (AS/RS) when the machine is idle is addressed. The objective of the pre-positioning strategy is to minimize the maximum response time to service incoming requests into the AS/RS. A model is developed under the operating condition that each machine can serve one or multiple dedicated aisle(s) of the system. The aisles are assumed to exist in the same region of the AS/RS and thus form a valid order storage/retrieval zone. A solution algorithm for determining the optimal dwell point or location is developed. The paper assumes a dynamic environment where orders arrive over time and are to be serviced by the S/R machine. A dwell point or strategic point to pre-position the machine is to be determined whenever the S/R machine becomes idle in anticipation of an incoming service request. A numerical example is provided to demonstrate how the technique can be used in an actual production setting to improve the overall order turnaround time.     

Closed form models for determining the optimal dwell point location in automated storage and retrieval systems

This paper examines the problem of where a storage/retrieval machine should reside, or dwell, when an automated storage and retrieval system (AS/RS) becomes idle to minimize the expected value of the next transaction time. After a review of the relevant literature on AS/RS dwell point strategies, this paper proposes several analytical models of these expected response times of the AS/RS based on the relative locations of the input and output ports of the AS/RS. It uses a continuous rack approximation to provide analytical models of the dwell point location problem. These models provide closed form solutions for the dwell point location in an AS/RS. Extensions are made to consider AS/RS with a variety of configurations including multiple input and output ports. These models not only provide solutions to the dwell point location problem, but they provide considerable insight into the nature of this problem, which is particularly valuable when the requirements facing the AS/RS are uncertain.     

Analytical Results for Miniload Throughput and the Distribution of Dual Command Travel Time

We determine the throughput, the maximum rate at which a miniload automated storage and retrieval system can process requests, as a'function of the dimension of the storage racks, the speed of the s/r machine and the speed of die picker. As a byproduct, we determine the distribution function of me travel time for a storage/retrieval machine that stores one container and retrieves another container (“dual command cycle”) before returning to the I/O point. Our emphasis is on obtaining closed-form, computable expressions.     

Optimising two dwell point policies for AS/RSs with input and output point at opposite ends of the aisle

Automated storage and retrieval systems (AS/RSs) are widely used for storing and retrieving products in all types of warehouses. Dwell point policy is a vital control policy that can greatly affect the performance of AS/RSs. In this paper, we study dwell point policies in AS/RSs with input and output stations at opposite ends of the aisle. We first propose two dwell point policies. We find that five existing dwell point policies in the literature are special cases of exactly one of our policies. We then develop expected travel time models for the proposed policies, solve these models with the objective of minimising expected travel time, and obtain closed-form solutions for the optimal dwell location(s). We prove that one proposed policy dominates the other in terms of expected travel time. Numerical experiments are performed to quantify the percentage gap of expected travel time between the proposed policies and policies in the literature. We find that, in some situations, the better proposed policy can achieve up to 8%–10% reduction in expected travel time in comparison with the best literature policy. A real-data case study validates that these situations arise with high probability in typical daily warehouse operations.     

The impact of dwell point policy in an Automated Storage/Retrieval System

Automated storage and retrieval systems (AS/RS) are devices that allow intensive storage of materials. They can improve the supply chain performance, assuring more available volume for storage, lower labour costs and higher handling throughput of warehousing. Furthermore, the automated control allows the probability of errors in storage and retrieval to be minimised, along with the probability of product damage during movements. The purpose of the paper is to find the best solution in order to find the optimal dwell point policy, among different rules, able to minimise the travel time and distance travelled by stacker cranes, and consequently warehousing costs. An original and innovative model was developed in order to investigate the dwell point position for random allocation of unit loads. A software platform was developed to validate the proposed model by computer simulations. The performance of the system was analysed in a parametric/continuous way, varying at the same time the number of spans and levels, the height of the input/output point and the interval between requested missions. The results show that the developed model allowed convenience areas to be identified among the policies in which the travel time, distance travelled, and consequently warehousing costs are minimised, by varying different parameters.     

Throughput performance of automated storage/retrieval systems under stochastic demand

In this paper we are concerned with the throughput performance of an Automated Storage/Retrieval (AS/R) system under stochastic demand, i.e., the case where storage and retrieval requests arrive randomly. Although AS/R systems have been the subject of extensive research, their performance under stochastic demand remains relatively unexplored. In fact, with random storage and retrieval requests, the primary tool for AS/R system analysis has been simulation. Assuming a particular dwell point strategy for the storage/retrieval machine, in this paper we derive closed-form analytical results to evaluate the performance of an AS/R system under stochastic demand and determine whether or not it meets throughput. Although the results are derived for a given system, they can also be used in the design or evaluation of new/proposed systems.     

Conceptualizing tools for autonomous vehicle storage and retrieval systems

Autonomous vehicle storage and retrieval systems utilize rail-guided vehicles moving in rectilinear paths within and between the aisles of unit load storage racks. Vertical vehicle movement is provided by lifts installed at fixed locations along the rack periphery. As an alternative to traditional automated storage and retrieval systems, autonomous vehicle systems enable users to match vehicle fleet size and the number of lifts to the level of transactions demand in a storage system. Analytical conceptualizing tools based on the features of autonomous vehicle systems are proposed for modelling expected performance as a function of key system attributes including storage capacity, rack configuration and fleet size. The models are demonstrated for a sample problem and compared with analytical conceptualizing tools used for automated storage and retrieval systems.     

Closed form models for dwell point locations in automated storage carousel systems

This research focuses on determining the optimal dwell point location in an automated storage carousel system (ASCS) to minimise the expected response time for incoming service requests (storages and retrievals). This can be achieved by modelling the problem as a minisum location problem on a line segment with two-dimensional existing facilities (demands) using a continuous approximation of the individual storage locations of the ASCS. Closed form solutions of the associated dwell point location problem have been provided for the two different cases used to model this problem. These two cases arise from the two possible different configurations of the ASCS parameters; the travel times in circumference and height.     

Performance evaluation of In-Deep Class Storage for Flow-Rack AS/RS

This article presents a new storage-retrieval method called In-Deep Class Storage, designed for Flow-Rack AS/RS. Class-based storage is a well-known method that has an extensive literature; our method is based on the fact that it is more efficient to dedicate the front layers of each bin to the class of the most popular items rather than dedicating whole bins close to the drop-off station. Clearly, this idea is not trivial to implement due to the dynamic behaviour of such racks. Thus, two separate algorithms have been defined, one for storage and one for retrieval, enabling dynamic use of our approach, with the only hypothesis of a Pareto distribution of item demand. This article presents a simulation study designed to compare the performance of random storage and retrieval with the use of the algorithms. This study shows a significant improvement of the expected retrieval delay, the main performance indicator selected for the study.     

An optimal storage assignment for automated rotating carousels

Automated rotating carousels (ARCs) are increasingly used as building blocks for material storage and control systems in factories to provide easy and quick access to materials. This technical note introduces a simple and robust storage assignment policy that minimizes the expected turnaround time for accessing an item in an automated rotating carousel. The policy is shown to be optimal for a class of dwell point strategies.     

Travel time models for deep-lane unit-load autonomous vehicle storage and retrieval system (AVS/RS)

Autonomous vehicle storage and retrieval systems use vehicles that move horizontally along rails within the storage racks, while vertical movements are provided by lifts. The solution proposed in this paper addresses a particular system configuration that works with multiple deep storage lanes that are widely used in the food and beverage industry, characterised by large volumes of products of limited variety. The generic deep lane is single item, i.e. one stock keeping unit, and single batch, i.e. one production lot, thereby affecting the performance of the system in terms of storage capacity utilisation and throughput. Determining the number and depth of the lanes is crucial to aid the design and control of such a storage system. The aim of this paper was to support the design of AVS/RSs though a set of original analytic models for the determination of the travelled distance and time for single-command and dual-command cycles given alternative layout configurations. The models are validated by simulation and exemplified with a real-warehousing case study. The paper presents useful guidelines for the configuration of the system layout including the determination of the optimal shape ratio and the length of the lanes.     

Travel-time models considering the operating characteristics of the storage and retrieval machine

Existing travel-time models of automated storage/retrieval systems (AS/RS) assume the average uniform velocity, ignoring the operating characteristics of storage/retrieval (S/R) machine such as the acceleration/deceleration rate and the maximum velocity. Consequently, the optimal design and schedule based on the existing models is far from optimal from the practical point of view. This paper presents continuous analytical models of travel time which integrate the operating characteristics of S/R machine. Using a randomized assignment policy, travel times are determined for both single and dual command cycles. The models developed are examined through discrete evaluation procedures.     

Travel-time model of dual-command cycles in a 3D compact AS/RS with lower mid-point I/O dwell point policy

Three-dimensional compact automated storage/retrieval systems (AS/RS) have been extensively applied in warehouses, with advantages of full automation, time efficiency and high space utilisation. While previous studies that use lower mid-point input/output (I/O) dwell point policy consider single-command cycles (SC), this paper builds travel-time models of dual-command cycles (DC). The S/R crane also dwells in the lower mid-point of the rack when it is idle. We validate analytical models using simulation and use analytical models to optimise system dimensions. Numerical experiments are used to compare DC with SC. The results show that DC outperform SC in terms of cycle time of one command.     

Dynamic Operational Policies in an Automated Warehouse

In this paper we consider the optimal relocation of pallets with a high expectancy of retrieval within each storage rack of an automated warehouse to meet the fluctuating, short-term throughput requirements imposed on the automated storage-retrieval machines. The prepositioning of these pallets closer to the input/output point of each rack during off-peak periods will reduce the expected travel time for the storage/retrieval machines during future peak periods of the planning horizon.

As the model has been abstracted from an actual operating environment, we first describe the environment in which the problem has been posed. We then exploit the special structure of the problem to develop conditions that an optimal relocation policy should satisfy. Based on these optimality conditions, we develop a very efficient optimal relocation algorithm. Finally, we present the performance of several relocation policies in the warehouse studied.     

Performance of carousel systems with ‘organ-pipe’ storage

It is well known that, for carousel systems, a dedicated storage, referred to as the ‘organ-pipe’ storage in the literature, is optimal with respect to the expected travel distance for processing successive requests. What remains unanswered is how to determine its performance, which is the motivation of this study. We consider bi-directional carousels under a ‘floating’ dwell point strategy. Two important performance measures considered are system capacity (maximum throughput) and job sojourn time. We also investigate the effect of activity skew on system performance.     

Travel time models for the rack-moving mobile robot system

The rack-moving mobile robot (RMMR) system is a special parts-to-picker automated warehousing system that uses hundreds of rack-moving machines to accomplish the repetitive tasks of storing and retrieving parts by lifting and transporting unit racks autonomously. This paper investigates the operation cycle of the rack-moving machine for storage and retrieval from the perspective of the lane depth, especially exploring the particularity of the RMMR system in multi-deep lanes, and proposes expected travel time models of the rack-moving machine for single- and multi-deep layouts of the RMMR system. To validate the effectiveness of the proposed models, an experimental simulation was conducted with a 1–4-deep layout under six scenarios of different numbers of aisles and layers, and results were compared with results obtained using proposed models. The paper presents useful guidelines for the configuration of the RMMR system layout including the determination of the optimal lane depth.     

钢货架结构研究现状与关键技术

随着物流和电商行业的飞速发展,钢货架结构从单纯提供货物存储功能的简单机械类产品逐步向高位立体库、库架合一式建筑发展,这对货架结构的安全性提出更高要求。与传统钢框架结构相比,钢货架结构的托盘货载远大于结构自重,竖向荷载活恒比值可达10∶1量级;主要竖向承重构件多采用连续开孔薄壁截面,其性能受到局部屈曲、畸变屈曲、整体屈曲以及各屈曲模式间相互作用的影响;梁柱节点和柱脚节点多为半刚性挂齿式机械连接,表现出强非线性和捏拢滑移滞回特征;竖向支撑体系对整体结构稳定性的影响机制和有效性。另外,在地震作用下,货架结构的破坏模式除了主要承重构件的破坏和整体结构的垮塌外,还存在托盘货载跌落导致的货物、结构破坏和人员伤害。在钢货架结构抗震分析中,托盘货物的滑动和跌落应属于一种极限状态加以考虑,托盘与横梁间的动力摩擦系数将成为评估结构性能的一个重要参数。结合国内外已有研究成果,该文基于钢货架结构的特点,评述了现有的研究方法,综述了各基本结构要素的力学行为、整体结构的稳定性态及抗震性能,探讨了研究中的关键问题。