Carrier Position Calculation Using Reflected Light Intensity Thresholds
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Solution Overview
Problem
Existing automatic carriers traveling on pathways face challenges in accurately determining their position due to interference from loads and environmental changes, which affect the data collected by distance measuring sensors.
Innovation Solution
The carrier system incorporates a distance measuring sensor, a map data storage unit, an approximate line calculation unit, and a position calculation unit, with reflecting plates placed along the pathway to filter data based on intensity thresholds, allowing for accurate calculation of the carrier's position by distinguishing between areas with significant and minor environmental changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the distance measuring sensor detects reflected light from all obstacles including loads, then the sensor can obtain pathway information, but the positional data becomes inaccurate due to interference from loads and environmental changes
Solution Approach 1:
The pathway is divided into first area (between racks where loads are placed) and second area (other areas). Different data processing strategies are applied to each area: in the first area, only measured data meeting intensity thresholds is used, while in the second area, all measured data is utilized. This segmentation resolves the contradiction by adapting the data selection criterion to the specific characteristics of each area.
Solution Approach 2:
Different quality criteria are applied to measured data depending on the location. In the first area, measured data must meet a predetermined intensity threshold to be considered high quality and usable. In the second area, all measured data is treated as acceptable. This local quality approach allows accurate position calculation in both areas despite different environmental conditions.
2Adaptability or versatility
If the carrier travels through areas with varying peripheral environments (first area between racks), then the carrier can access loads, but the measured data changes according to load presence and size, affecting position calculation accuracy
Solution Approach 1:
The data selection criterion dynamically changes based on the carrier's location. When in the first area, the system applies intensity threshold filtering to measured data. When in the second area, the system uses all measured data without threshold filtering. This dynamic adaptation allows the carrier to operate versatilely in load areas while maintaining position calculation accuracy.
3Measurement precision
If reflecting plates are provided along the pathway in the first area, then the light reflection intensity increases and can be distinguished from other objects, but the device complexity increases
Solution Approach 1:
Reflecting plates are introduced as intermediary objects attached to rack columns in the first area. These plates enhance light reflection intensity, making it easier to distinguish pathway structures from loads. The reflecting plates are simple components that can be easily attached to existing rack structures, minimizing the increase in overall device complexity while significantly improving 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 approach enables the carrier to correctly calculate its position even in dynamic environments by isolating data from reflecting plates and using all data in stable areas, improving accuracy and robustness against environmental changes.
Implementation Method 1
the distance measuring sensor measures an intensity of reflected light a plurality of times, and obtains a plurality of pieces of measured data
Data Source
AI summary
A carrier which automatically travels on a pathway. A carrier comprising: a carrier main body which travels on the pathway including a first area and a second area other than the first area; a distance measuring sensor which is provided in the carrier main body, measures an intensity of reflected light a plurality of times, and obtains a plurality of pieces of measured data; a map data storage unit which stores map data in which structures provided along the pathway are recorded; an approximate line calculation unit which calculates an approximate line based on a set of pieces of measured data having the light intensity equal to or more than a predetermined threshold among the plurality of pieces of measured data in the first area and calculates the approximate line based on the set of the plurality of pieces of measured data in the second area; and a position calculation unit which calculates a position of the carrier main body by collating the approximate line and the map data.