AGV Load Collapse Detection Using LiDAR Detection Zones
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Solution Overview
Problem
Existing load collapse detection systems for automated guided vehicles require the installation of additional sensors, incurring time and costs, and there is a need for a more efficient method to accurately detect load collapses while traveling.
Innovation Solution
A load collapse detection device using existing LiDAR sensors installed on automated guided vehicles to detect objects in specific ranges, determining load collapses by monitoring changes in detected objects within defined detection zones, and updating these zones based on vehicle state and load characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a complex sensor system is used to detect load collapse, then detection accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the detection function from complex sensor systems and implements it using the existing, simpler drive unit components. The drive unit's motor current and rotational speed data are repurposed to detect load collapse, eliminating the need for separate complex sensors while maintaining detection capability through intelligent analysis of existing operational parameters.
Solution Approach 2:
The drive unit performs self-diagnosis by monitoring its own operational parameters (motor current, rotational speed) to detect load collapse. This self-service approach allows the system to detect abnormalities without requiring external complex sensing systems, reducing overall device complexity while maintaining detection accuracy.
2Reliability
If frequent inspections are conducted to ensure safety, then safety reliability is improved, but productivity decreases
Solution Approach 1:
The detection system operates continuously during normal conveyance operations without requiring separate inspection periods. The drive unit constantly monitors motor current and rotational speed, enabling real-time load collapse detection that maintains safety reliability while avoiding interruptions to productivity, as the detection occurs seamlessly during regular operation.
Solution Approach 2:
The system provides continuous feedback on load status through monitoring of drive unit parameters. This real-time feedback mechanism allows immediate detection of load collapse conditions without requiring periodic manual inspections, maintaining high safety reliability while ensuring uninterrupted conveyance operations and maximizing productivity.
Data Source
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AI summary
A load collapse detection device (60A) in an automated guided vehicle (1A) includes a detection range information storage unit (40), an object detection processing unit (32A), and a load collapse determination unit (33). The detection range information storage unit (40) stores information indicating a load collapse detection range adjacent to the automated guided vehicle (1A) and information indicating an obstacle detection range in a periphery of the load collapse detection range. The object detection processing unit (32A) acquires a detection result performed by object detection sensors (10-1 and 10-2) detecting objects in a periphery of the automated guided vehicle (1A) while the automated guided vehicle (1A) is travelling, and detects objects in the load collapse detection range and objects in the obstacle detection range. When an object in the load collapse detection range is detected, the load collapse determination unit (33) determines that the object has fallen due to load collapse when the object has not been detected in the obstacle detection range before being detected in the load collapse detection range.