Autonomous Bot Position Sensing for Precise Shelf Alignment
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Solution Overview
Problem
Existing storage and retrieval systems face challenges in accurately locating and positioning autonomous transport vehicles relative to case holding areas in warehouses, which affects the efficient picking and placement of case units.
Innovation Solution
The implementation of a storage and retrieval system that utilizes multilevel vertical conveyors and autonomous transport vehicles equipped with sensors and positioning systems, such as beam sensors and proximity sensors, to determine their location within the storage structure, allowing precise alignment and interaction with storage shelves and conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated transports are used to transport cases to and from storage racks, then productivity is improved, but measurement precision of bot position relative to case holding area deteriorates
Solution Approach 1:
The patent introduces an intermediary positioning system consisting of markers placed on storage racks and corresponding sensors on autonomous bots. This intermediary mechanism enables precise position detection without compromising transport automation, resolving the contradiction between automated transport efficiency and position measurement accuracy.
Solution Approach 2:
The patent replaces mechanical position sensing methods with optical sensing using markers and sensors. This substitution allows for non-contact, high-precision position detection that works seamlessly with automated transport systems, maintaining both productivity and measurement precision.
2Measurement precision
If sensors are added to autonomous transport vehicles for position sensing, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the positioning function from the bot's internal systems and separates it into independent markers on racks and sensors on bots. This extraction simplifies the overall system by making position detection a separate, modular function that can be optimized independently from the transport mechanism.
Solution Approach 2:
The marker-sensor system serves multiple functions: position detection, alignment guidance, and speed measurement. This multi-functionality reduces the need for separate systems for each function, thereby reducing overall device complexity while maintaining high measurement precision.
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
This solution enables accurate and efficient transfer of case units between storage and retrieval systems, improving the operational efficiency and flexibility of warehouse operations by ensuring precise positioning and alignment of autonomous transport vehicles.
Implementation Method 1
beam sensors and proximity sensors, to determine their location within the storage structure
Implementation Method 2
beam sensors and proximity sensors, to determine their location within the storage structure
Data Source
AI summary
A storage and retrieval system including a storage structure having storage shelves, each storage shelf having slats for supporting stored items where the slats are spaced apart from each other by a predetermined distance, an autonomous transport vehicle including at least one sensor configured to sense each of the slats and output a signal indicating when a slat is sensed, and a controller for verifying a location of the autonomous transport vehicle within the storage structure based on at least the output signal.