Conveyor Unit Obstacle Detection with Integrated Optical Safety
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Solution Overview
Problem
Conveyor systems with free-moving units lack effective monitoring of their route, leading to potential obstacles from objects or people, which can compromise safety and flexibility.
Innovation Solution
Integration of a safety system with an optical detection device, including a laser and camera, that generates a detection image to detect obstacles in the travel path, allowing for real-time monitoring and communication with a central controller to adjust the conveyor units' movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety system with optical detection device is integrated into the conveyor unit, then the ability to detect obstacles and ensure safe operation is improved, but the device complexity increases
Solution Approach 1:
The electrical supply cable is designed to perform multiple functions: it supplies electrical energy to the conveyor unit, transmits sensor signals, serves as a traction cable for direction correction, and now also carries the optical detection device for obstacle detection. This multi-functional integration improves safety without proportionally increasing complexity.
Solution Approach 2:
The optical detection device is integrated with the electrical supply cable system rather than being a separate component. The camera and laser device are mounted on the conveyor unit in a way that combines multiple functions (power supply, control signaling, and safety monitoring) into a unified system architecture.
2Measurement precision
If the fan beam is tilted at an angle to generate a detection line, then the detection precision for obstacles at different distances is improved, but the device complexity increases
Solution Approach 1:
The laser device is tilted at a specific angle (5°-15°) relative to the horizontal plane to create a fan beam that forms a detection line. This parameter change in the laser orientation enables the system to detect obstacles at various distances along the conveyor path, with closer obstacles appearing higher on the detection line, thereby improving measurement precision without requiring multiple sensors.
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
Ensures the route is clear of obstacles, maintaining system flexibility while preventing accidents by detecting and responding to objects or irregularities in the path, ensuring safe operation and adaptability.
Implementation Method 1
the image generation device can generate a jet fan that is tilted from a horizontal plane at an angle α about a tilting axis that runs horizontally and perpendicularly to the longitudinal axis of a conveyor unit and is emitted into the travel path of the conveyor unit
Data Source
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AI summary
A conveyor unit for conveying loaded or unloaded load carriers (12) comprises an undercarriage (24) which can be moved on floor wheels (26), and a carrier element (28) which is entrained by the undercarriage (24) and can be raised or lowered in relation to the undercarriage (24) such that when the conveyor unit is empty it is able to move underneath a load carrier (12) and when it is in a conveying configuration it is able to pick up a load carrier (12) with the carrier element (28) and convey said load carrier. By means of a drive system (30) at least one of the floor wheels (26) and the carrier element (28) can be driven. A safety system (60) is carried along, by means of which obstacles can be detected, which are located in the travel path of the conveyor unit (20) and interfere with the onward travel of the conveyor unit (20). The invention further relates to a conveyor system for conveying loaded or unloaded load carriers (12) having several conveyor devices (18), in which each of the conveyor devices (18) comprises at least two cooperating conveyor units (20) of the above kind.