Three-dimensional goods shelf inclination detection system

Abstract

The invention relates to the technical field of storage goods shelves, in particular to a three-dimensional goods shelf inclination detection system which comprises an ultrasonic distance measuring sensor installed on a goods shelf stand column and used for measuring the distance between a goods shelf and a reference plane. The vibration sensors are installed at the bottom of the goods shelf and on the goods carrying table of the stacking machine and used for monitoring the vibration frequency and amplitude of the goods shelf structure in real time; the controller is used for receiving and processing data from the ultrasonic ranging sensor and the vibration sensor and judging the inclination state of the goods shelf according to the data; and the data processing unit is used for analyzing the monitoring data transmitted by the controller and providing real-time monitoring, data recording, historical analysis and alarm functions, and real-time monitoring of multi-point positions of the goods shelf is achieved by integrating the ultrasonic distance measuring sensor, the vibration sensor and the automatic calibration module.

Description

Technical Field

[0001] The invention relates to the technical field of storage shelves, and more specifically, to a three-dimensional shelf tilt detection system. Background Art

[0002] In modern warehousing and logistics industries, three-dimensional racking systems are widely used in various warehouses and distribution centers due to their efficient space utilization and automation characteristics. However, with the increase in rack height and storage density, problems such as rack tilt, vibration, and structural instability are becoming increasingly prominent, which may lead to rack collapse, damage to goods, and even threaten personnel safety.

[0003] In view of the above problems, for example, the announcement number CN114964365A discloses an automated three-dimensional warehouse shelf anti-tilt detection system and anti-tilt detection method, which measures the horizontality and verticality of the shelf by means of a level measuring instrument and a laser rangefinder installed on a stacker. The measurement data is processed and stored by a controller, and is used to monitor the tilt state of the shelf, thus avoiding the cost and defects caused by manual measurement. Through data calculation and statistical procedures, the tilt angle detection of the three-dimensional warehouse shelf at each cargo sampling point can be realized, and the data is written into a database, realizing online detection of the verticality and horizontality of the shelf column. The angle measurement sensor installed on the stacker is a diffuse reflection photoelectric sensor, which has a high cost, and is affected by light in a large warehouse environment, resulting in low detection accuracy.

[0004] There is also a shelf tilt monitoring and early warning system disclosed in announcement number CN117073634A, which uses a light source, a plane mirror, and a light sensor to monitor the tilt of the shelf. The light source is located at the top of the shelf, and the plane mirror is installed at the bottom of the shelf. The reflected light signal is received by the light sensor and converted into an electrical signal. The tilt of the shelf can be determined by the change of the signal. When the shelf tilts and there is a natural shake, the two inclinations detected by the two sets of sensors will change. When the difference in the amplitude of the two changes is maintained within a certain limit, it can be determined that the change is a natural change, or the change frequency is within the normal range. It can be determined that the change is a natural change, and no alarm is issued. This prior art also uses a light sensor to judge. The optical system is sensitive to the lighting conditions of the environment and is affected by the changes in light in the warehouse. The system installation is complicated and requires precise calibration of the positions of the light source, plane mirror, and sensor to ensure detection accuracy. Summary of the invention

[0005] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a more comprehensive and efficient three-dimensional shelf tilt detection system, which aims to solve the problems of high cost, susceptibility to interference in detection accuracy, complex installation, and inaccurate distinction between natural shaking in the prior art by integrating multiple sensor technologies and intelligent data processing methods, thereby providing a more stable and reliable shelf tilt monitoring and early warning function to ensure the safety and operation efficiency of the warehousing system.

[0006] To achieve the above object, the present invention provides the following technical solutions: A three-dimensional shelf tilt detection system, comprising: An ultrasonic distance measuring sensor installed on a shelf column, the ultrasonic distance measuring sensor is used to measure the distance between the shelf and a reference plane; Vibration sensors installed at the bottom of the shelf and on the loading platform of the stacker, which are used to monitor the vibration frequency and amplitude of the shelf structure in real time; A controller, the controller is used to receive and process data from the ultrasonic ranging sensor and the vibration sensor, and determine the tilt state of the shelf according to the data; The data processing unit is used to analyze the monitoring data transmitted by the controller and provide real-time monitoring, data recording, historical analysis and alarm functions.

[0007] The present invention is further configured as follows: ultrasonic distance measuring sensors are installed at the bottom, middle and top of the shelf columns to respectively monitor the distance differences between the bottom, middle and top of the column and the reference plane.

[0008] The present invention is further configured as follows: the vibration sensor comprises a plurality of first vibration sensors installed on shelf columns and a second vibration sensor installed on a stacker loading platform, the first vibration sensor being used to monitor the overall vibration of the shelf columns, and the second vibration sensor being used to monitor the dynamic response of the shelf during stacker operation.

[0009] The present invention is further configured as follows: the reference plane is a reflective plate arranged on an adjacent shelf corresponding to the ultrasonic ranging sensor, and the reflective plate and the signal collection end of the ultrasonic ranging sensor are arranged vertically.

[0010] The present invention is further configured as follows: the data processing unit includes a tilt prediction module, which establishes a prediction model for the shelf tilt trend by analyzing the ultrasonic ranging data and the vibration data, and warns of possible tilt risks in advance based on the prediction results.

[0011] The present invention is further configured as follows: the reflective plate is connected to the shelf through a connecting piece, the connecting piece includes a base portion and a top portion, the base portion is provided with a plurality of openings, the top portion includes two clamping plates, the two clamping plates are movably connected, and a accommodating cavity is formed between the two clamping plates.

[0012] The present invention is further configured as follows: the front side of the reflector is concave, and a docking component connected to the cavity is provided on the back side of the reflector. The docking component includes a rod and a sphere, and the sphere extends into the accommodating cavity.

[0013] The present invention is further configured as follows: the data processing unit also includes an adaptive adjustment module, and the adaptive adjustment module adjusts the parameters of the tilt prediction model in real time according to environmental parameters and system operating status to ensure the prediction accuracy under different environmental conditions.

[0014] The present invention is further configured as follows: the data processing unit also includes a remote communication module, and the remote communication module is used to transmit the monitoring data and alarm information to a central monitoring room or a cloud platform to achieve remote monitoring and management.

[0015] The present invention is further configured to include an automatic calibration module, which is connected to the ultrasonic distance measuring sensor and the vibration sensor to compensate for measurement errors caused by temperature changes, structural deformation or sensor aging.

[0016] Compared with the shortcomings of the prior art, the beneficial effects of the present invention are: By integrating ultrasonic ranging sensors, vibration sensors and automatic calibration modules, real-time monitoring of multiple positions of shelves is achieved. Unlike the existing technology that relies on a single type of sensor, the present invention can more accurately capture the slight tilt and vibration of the shelf, improving the overall detection accuracy, especially in high shelves and complex storage environments, and can effectively avoid false alarms and missed alarms.

[0017] By optimizing sensor layout and adopting precise data processing algorithms, hardware costs can be reduced without sacrificing accuracy, especially in large-scale warehousing environments.

[0018] By analyzing ultrasonic ranging data and vibration data, a prediction model for shelf tilt trends was established, which can provide early and accurate warning of potential tilt risks and provide sufficient response time for warehousing operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural schematic diagram of the present invention; Figure 2 It is a schematic diagram of the module of the present invention; Figure 3 The structure of the reflector and the connector of the present invention is shown in FIG. Figure 1 ; Figure 4 The structure of the reflector and the connector of the present invention is shown in FIG. Figure 2 .

[0020] Shelf 1, stacker 2, ultrasonic distance sensor 3, reflector 4, connector 5, base 51, top 52, docking component 6, rod 61, sphere 62, guide rod 7, opening slot 510, and movable hole 501. DETAILED DESCRIPTION

[0021] Reference Figures 1 to 4 The embodiments of the present invention are further described.

[0022] This embodiment specifically includes: an ultrasonic ranging sensor 3 installed on the column of the shelf 1, and the ultrasonic ranging sensor 3 is used to measure the distance between the shelf 1 and a reference plane; the reference plane is a reflector 4 set on the adjacent shelf 1 corresponding to the ultrasonic ranging sensor 3, and the reflector 4 and the signal collection end of the ultrasonic ranging sensor 3 are vertically arranged.

[0023] Vibration sensors installed at the bottom of shelf 1 and on the loading platform of stacker 2 are used to monitor the vibration frequency and amplitude of the shelf 1 structure in real time.

[0024] A controller, the controller is used to receive and process data from the ultrasonic ranging sensor 3 and the vibration sensor, and determine the tilt state of the shelf 1 according to the data; The data processing unit is used to analyze the monitoring data transmitted by the controller and provide real-time monitoring, data recording, historical analysis and alarm functions.

[0025] The automatic calibration module is connected to the ultrasonic distance measuring sensor 3 and the vibration sensor to compensate for the measurement error caused by temperature change, structural deformation or sensor aging.

[0026] The automatic calibration module includes a calibration control unit, a temperature and environment monitoring unit, a reference signal source, a self-test and diagnosis unit, an adjustment and compensation unit, and a data storage and recording unit.

[0027] Calibration Control Unit: Consists of an embedded processor that is responsible for executing the calibration algorithm, managing the calibration process, and adjusting sensor parameters.

[0028] Temperature and environment monitoring unit: It consists of temperature sensors, humidity sensors, etc., integrated in the module, used to monitor environmental conditions in real time, and provide real-time environmental data to the calibration control unit for adjusting the compensation parameters in the calibration model.

[0029] Reference signal source: Provides known standard distance or vibration signals for calibrating the measurement accuracy of the sensor. These reference signals are measured regularly by the ultrasonic distance sensor 3 or the vibration sensor to calibrate the measurement error.

[0030] Self-Test and Diagnostic Unit: Contains built-in test and diagnostic circuits to detect the status and health of the sensor, perform periodic self-tests to detect whether the sensor is faulty or deviated, and provide feedback to the calibration control unit to adjust the sensor's calibration parameters.

[0031] Adjustment and compensation unit: It consists of a digital gain control circuit, a digital-to-analog converter (DAC), and a programmable logic controller, and is responsible for implementing the instructions of the calibration control unit.

[0032] The ultrasonic distance measuring sensors 3 are installed at the bottom, middle and top 52 of the column of the shelf 1 to monitor the distance difference between the bottom, middle and top of the column and the reference plane respectively.

[0033] The vibration sensor includes a plurality of first vibration sensors installed on the columns of the shelf 1 and a second vibration sensor installed on the loading platform of the stacker 2. The first vibration sensor is used to monitor the overall vibration of the columns of the shelf 1, and the second vibration sensor is used to monitor the dynamic response of the shelf 1 during the operation of the stacker 2.

[0034] The data processing unit includes a tilt prediction module, which establishes a prediction model for the tilt trend of shelf 1 by analyzing the ultrasonic ranging data and the vibration data, and warns of possible tilt risks in advance based on the prediction results.

[0035] Through time series analysis, the tilt trend and dynamic changes of shelf 1 can be captured, and a model can be established to predict the future tilt state. The prediction model is an autoregressive moving average model. An adaptive module, namely Kalman filtering, is added to the prediction model to integrate the data of vibration sensors and ultrasonic ranging sensors 3 to form an accurate judgment of the tilt state of shelf 1.

[0036] Based on the derivative analysis of the time series, a differential equation model is established to describe the relationship between signal changes and time. By solving the differential equation, the dynamic change curve of the tilt degree of shelf 1 can be obtained, and the tilt state at a future time point can be predicted.

[0037] First, the measurement data is acquired from the ultrasonic ranging sensor 3 and the vibration sensor in real time. Assume that at time t At time , the measured inclination (e.g., distance or angle) is , so over time The measured tilt forms a time series:

[0038] To describe the degree of inclination With the dynamic change over time, a second-order linear ordinary differential equation is established:

[0039] is a function of the degree of tilt over time; is the first-order derivative, indicating the rate of change of tilt; is the second-order derivative, which represents the acceleration of the tilt change; is a constant coefficient, reflecting the physical characteristics of the system; It is an external input or disturbance, a change caused by external forces, vibrations or other factors.

[0040] Function obtained by solving differential equations It can be used to predict the tilt degree of shelf 1 at a future moment.

[0041] is the part of the special solution, according to Decide; is the real part of the characteristic equation, reflecting the exponential decay or growth of the system; It is the imaginary part of the characteristic equation and reflects the oscillation frequency of the system.

[0042] By adding a future time point Substitution , predicting the degree of tilt at future time points.

[0043] The reflector 4 is connected to the shelf 1 through a connector 5. The connector 5 includes a base 51 and a top 52. The base 51 is provided with a plurality of openings. The top 52 includes two clamping plates, which are movably connected, and a receiving cavity 50 is formed between the two clamping plates. The front of the reflector 4 is concave. A docking component 6 connected to the cavity is provided on the back of the reflector 4. The docking component 6 includes a rod 61 and a sphere 62. The sphere 61 extends into the receiving cavity 50. A movable hole 501 is provided on the clamping plate. After a screw passes through the movable holes 501 on the two clamping plates, a nut is connected at one end of the screw to squeeze the clamping plate, thereby squeezing the sphere 62 by the clamping plate to fix the position of the reflector 4. The end surface where the clamping plate contacts the sphere 62 is concave with an arc-shaped concave that matches the sphere. A guide rod 7 is provided on the base portion 51, and one end of the two clamping plates has a hole that is sleeved on the guide rod, so that the clamping plates can slide on the guide rod by using the hole. An open groove 510 is provided on the base portion 51 for plugging into the shelf 1, and a threaded hole for screw connection is provided on the outer wall of the base portion 51. The connecting piece 5 and the shelf 1 are fixedly installed by the cooperation of the screw and the open groove 510.

[0044] The data processing unit also includes a remote communication module, which is used to transmit monitoring data and alarm information to a central monitoring room or a cloud platform to achieve remote monitoring and management.

[0045] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Common changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included in the protection scope of the present invention.

Claims

1. A three-dimensional shelf tilt detection system, characterized in that: include An ultrasonic distance measuring sensor installed on a shelf column, the ultrasonic distance measuring sensor is used to measure the distance between the shelf and a reference plane; Vibration sensors installed at the bottom of the shelf and on the loading platform of the stacker, which are used to monitor the vibration frequency and amplitude of the shelf structure in real time; A controller, the controller is used to receive and process data from the ultrasonic ranging sensor and the vibration sensor, and determine the tilt state of the shelf according to the data; The data processing unit is used to analyze the monitoring data transmitted by the controller and provide real-time monitoring, data recording, historical analysis and alarm functions.

2. A three-dimensional shelf tilt detection system according to claim 1, characterized in that: Ultrasonic ranging sensors are installed at the bottom, middle and top of the shelf columns to monitor the distance difference between the bottom, middle and top of the column and the reference plane respectively.

3. A three-dimensional shelf tilt detection system according to claim 2, characterized in that: The vibration sensor includes a plurality of first vibration sensors installed on the shelf columns and a second vibration sensor installed on the stacker loading platform. The first vibration sensor is used to monitor the overall vibration of the shelf columns, and the second vibration sensor is used to monitor the dynamic response of the shelf during the operation of the stacker.

4. The three-dimensional shelf tilt detection system according to claim 2, characterized in that: The reference plane is a reflective plate arranged on an adjacent shelf corresponding to the ultrasonic ranging sensor, and the reflective plate and the signal collection end of the ultrasonic ranging sensor are arranged vertically.

5. The three-dimensional shelf tilt detection system according to claim 2, characterized in that: The data processing unit includes a tilt prediction module, which establishes a prediction model for the tilt trend of the shelf by analyzing the ultrasonic ranging data and the vibration data, and warns of possible tilt risks in advance according to the prediction results.

6. The three-dimensional shelf tilt detection system according to claim 2, characterized in that: The reflective plate is connected to the shelf through a connecting piece, the connecting piece includes a base part and a top part, the base part is provided with a plurality of openings, and the top part includes two clamping plates, the two clamping plates are movably connected, and a containing cavity is formed between the two clamping plates.

7. A three-dimensional shelf tilt detection system according to claim 6, characterized in that: The front side of the reflecting plate is concave, and a docking component connected to the cavity is arranged on the back side of the reflecting plate. The docking component comprises a rod body and a sphere, and the sphere extends into the accommodating cavity.

8. The three-dimensional shelf tilt detection system according to claim 5, characterized in that: The data processing unit also includes an adaptive adjustment module, which adjusts the parameters of the tilt prediction model in real time according to environmental parameters and system operating status to ensure the prediction accuracy under different environmental conditions.

9. The three-dimensional shelf tilt detection system according to claim 6, characterized in that: The data processing unit also includes a remote communication module, which is used to transmit monitoring data and alarm information to a central monitoring room or a cloud platform to achieve remote monitoring and management.

10. The three-dimensional shelf tilt detection system according to claim 9, characterized in that: The invention also comprises an automatic calibration module, which is connected to the ultrasonic distance measuring sensor and the vibration sensor to compensate for the measurement error caused by temperature change, structural deformation or sensor aging.

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