Container Stack Abnormality Detection via Code Position Analysis
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Solution Overview
Problem
In automated container storage and retrieval systems, improperly stacked containers can lead to inefficient and unsafe conveyance, as they may be inclined or displaced, causing issues during transfer and storage, necessitating a means to detect and correct abnormal stacking before they reach the conveyance destination.
Innovation Solution
An abnormality detection device that uses code display surfaces on containers, a code reading system, and calculation processing to determine the alignment and positional displacement of containers, allowing for automatic detection and sorting of improperly stacked containers on the conveyance path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stacking operations are performed to stack containers in the storage area, then the storage operation can be performed, but the labor intensity and time consumption increase significantly
Solution Approach 1:
The system uses code reading means to automatically detect container identification information and determine stacking abnormalities without manual intervention. The container stack is self-inspected through automated optical detection, eliminating the need for manual stacking operations and their associated time losses.
Solution Approach 2:
Manual mechanical stacking operations are replaced by an automated detection system using code reading means (optical scanning). The system substitutes human labor with automated optical detection and computational analysis to identify stacking abnormalities, significantly improving efficiency.
2Productivity
If container stacking is not monitored, then the conveyance process continues without interruption, but improperly stacked containers may cause unsafe transfer and storage issues
Solution Approach 1:
The code reading means continuously monitors container stacks during conveyance and provides real-time feedback on stacking abnormalities. When improper stacking is detected, the system can trigger alerts or divert the container stack, ensuring safety issues are identified and addressed while maintaining overall conveyance continuity.
Solution Approach 2:
The detection system identifies stacking abnormalities before the container stack reaches the storage area or transfer point. By detecting issues in advance during conveyance, the system allows for preliminary correction or diversion, preventing unsafe conditions from developing into actual safety incidents.
3Measurement precision
If automated detection systems are installed to monitor container stacking, then stacking abnormalities can be detected, but the device complexity increases
Solution Approach 1:
Instead of using complex mechanical measurement devices to physically measure container positions, the system uses code reading means to capture images of identification codes on containers. The code positions serve as proxies for container positions, allowing stacking abnormality detection through simpler optical imaging and image processing techniques.
Solution Approach 2:
The identification code on the container acts as an intermediary element. Rather than directly measuring container physical dimensions and positions with complex sensors, the system reads the code's position and orientation in the image to infer stacking status, simplifying the detection mechanism while maintaining accuracy.
4Ease of operation
If code reading means is used to detect container positions, then stacking abnormalities can be identified, but the system requires clear line of sight and proper lighting conditions
Solution Approach 1:
The code reading means serves multiple functions: it reads container identification information for tracking purposes and simultaneously detects stacking abnormalities by analyzing code position and orientation in the captured image. This multi-functionality reduces the need for separate dedicated detection devices, simplifying the overall system while maintaining detection capability under various lighting conditions.
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 accurate and efficient detection of stacking abnormalities, preventing unsafe transfer and storage by automatically identifying and diverting or correcting improperly stacked container stacks, utilizing existing code reading technology to ensure proper alignment and positioning.
Implementation Method 1
a code reading means (12) which captures images of the code display surfaces (6) on the respective containers (1) in the container stack (8)
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
This abnormality detection device for a container stack determines stacking abnormality in a container stack 8 on a conveyance path 10. A plurality of containers 1, each of which is provided with a code display surface 6 on which container information is recorded at a fixed position on a lateral outer surface thereof, are stacked so that the code display surfaces 6 thereof are positioned on the same side, thereby forming a container stack 8. A code reading means 12 that captures an image of the code display surface 6 on each of the containers 1 is arranged on a lateral side of the conveyance path 10, said conveyance path 10 conveying the container stack 8 with the code display surfaces 6 oriented parallel to the conveyance direction. Read data from the code reading means 12 is input into a calculation processing means 18 that detects the position coordinate value of at least one fixed point on each of the code display surfaces 6 from the read data for each code display surface 6 and determines stacking abnormality in the container stack 8 from the position coordinate values.