AGV Load Positioning via Laser Scanning for Dense Storage
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Solution Overview
Problem
Automated guided material handling vehicles (AGVs) face limitations in densely packed warehouse environments due to safety standards requiring wider spacing between pallets, reducing storage capacity compared to manually operated vehicles.
Innovation Solution
A material handling vehicle equipped with a load carrier, control unit, drive motor, hydraulic system, and load sensor devices that determine the outermost points of pallets to enable precise positioning and reduce inter-pallet distance, allowing for denser storage without compromising safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If AGVs operate in warehouse with standard safety spacing, then safety is ensured, but storage capacity decreases due to wider spacing requirements
Solution Approach 1:
The patent replaces manual measurement and positioning methods with automated optical sensors (laser scanners) and electronic control systems. The sensor device scans pallet positions and the control unit calculates distances electronically, substituting mechanical measurement tools and human judgment with automated sensing and computation systems.
Solution Approach 2:
The patent changes the measurement parameter from fixed standard distances to actual measured distances between pallets. By using sensors to detect the true position of pallets and calculating actual inter-pallet distances, the system adapts spacing to real conditions rather than applying rigid standard values, enabling optimization of storage density while maintaining safety.
2Ease of operation
If AGVs use fixed clearance tolerances, then operation is simplified, but measurement precision is insufficient to achieve optimal spacing
Solution Approach 1:
The patent implements a feedback loop where sensors continuously scan pallet positions, the control unit calculates actual distances, compares them with safety requirements, and adjusts positioning accordingly. This closed-loop feedback system maintains both operational simplicity through automation and high measurement precision through continuous monitoring and adjustment.
Solution Approach 2:
The patent performs preliminary scanning and measurement of pallet positions before final positioning decisions are made. The sensor device scans and identifies pallet locations in advance, allowing the control unit to calculate required spacing and plan positioning movements beforehand, ensuring both precision and operational efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables AGVs to operate with the same clearance tolerances as manual vehicles, improving operational efficiency and storage density by accurately determining and maintaining the necessary distances between pallets, thus enhancing warehouse storage capacity.
Implementation Method 1
A hydraulic system, comprising at least one hydraulic pump, powered by a pump motor, and the necessary piping for powering hydraulic cylinders in particular for lifting and operating the load carrier
Implementation Method 2
A first laser sensor device, arranged to move in a horizontal direction, in particular transversally to the extension direction of the forks, is comprised in the vehicle
Data Source
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AI summary
Material handling vehicle (1) comprising a first load sensor device (8) that may detect the position including an angle of a load on a pallet as the load is carried by the load carrier (2) of the material handling vehicle (1). The disclosure also includes a method for operating a material handling vehicle (1) where the position of a load (21) is determined as the load (21) is carried by the load carrier (2). A software reproducing the method is also disclosed.