ASRS Container Camera Inspection Without Warehouse Shutdowns
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Solution Overview
Problem
Inspection of automated storage and retrieval systems is difficult due to the lack of aisles or access in traditional warehouse setups, leading to infrequent or incomplete inspections, which can result in increased system failures and unknown wear and tear.
Innovation Solution
A method using a camera and processor within a container transported by a container-handling vehicle to inspect the system, processing images locally to determine system characteristics and transmitting only relevant data, reducing communication traffic and allowing continuous system operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual inspection is performed by shutting down the system, then inspection accessibility is improved, but system productivity deteriorates due to shutdown time
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system. A camera mounted on a container-handling vehicle captures images of system components, and a processor automatically analyzes these images to detect wear and tear. This substitution eliminates the need for manual shutdowns and physical access by workers, resolving the contradiction between inspection accessibility and system productivity.
Solution Approach 2:
The inspection system enables the automated storage and retrieval system to inspect itself without external intervention. The container-handling vehicle, which is part of the system, transports the camera to inspection locations, and the processor analyzes images of system components. This self-inspection capability allows continuous operation while maintaining inspection effectiveness.
2Duration of action of moving object
If inspection intervals are extended due to access difficulty, then system operational time is improved, but system reliability deteriorates due to undetected wear and tear
Solution Approach 1:
The automated optical inspection system replaces manual inspection methods, enabling frequent monitoring without extending operational intervals. The camera and processor can rapidly capture and analyze images of multiple components, providing timely detection of wear and tear while maintaining continuous system operation.
Solution Approach 2:
The inspection system provides continuous feedback on system component conditions through automated image analysis. The processor detects wear and tear characteristics and can alert operators to potential failures before they occur, enabling proactive maintenance that preserves both operational duration and system reliability.
3Measurement precision
If manual inspection is performed frequently, then measurement precision is improved, but loss of time increases due to repeated shutdowns
Solution Approach 1:
The automated camera-based inspection system replaces manual visual inspection, providing consistent and precise measurement of component conditions without requiring system shutdowns. The optical system can detect subtle signs of wear and tear that might be missed by human inspectors, maintaining high measurement precision while eliminating shutdown time losses.
Data Source
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Figure 3A~3B
AI summary
The disclosure relates to a method of inspecting an automated storage and retrieval system, comprising providing a container including at least one camera and a first processor, controlling a container handling vehicle to pick up the container including the at least one camera and transporting the container to a first position, controlling the camera to capture at least one image, processing the at least one image using the first processor to determine a first characteristic of the at least one image representative of the state of the automated storage and retrieval system.