Drone Inspection for Disabled Storage Robots in Low-Ceiling Warehouses
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated storage and retrieval systems face challenges in accurately locating and visually inspecting malfunctioning autonomous container-handling vehicles, especially in large systems with low ceiling heights, where visual confirmation is difficult and often requires costly manual inspections.
Innovation Solution
A method utilizing a flying drone controlled by the exception handler module to navigate and visually inspect malfunctioning vehicles, employing optical sensors and preprogrammed search patterns to identify the precise location of disabled vehicles, with the option for human operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to locate malfunctioning vehicles, then visual confirmation can be obtained, but system shutdown is required and inspection costs increase
Solution Approach 1:
The patent introduces an autonomous ground vehicle as an intermediary device equipped with sensors (cameras, LIDAR, RFID readers) to locate and inspect malfunctioning vehicles. This mediator can navigate to the malfunctioning vehicle's position, capture images, and communicate location data back to the control system, eliminating the need for manual inspection and system shutdown while maintaining high location accuracy
Solution Approach 2:
The patent replaces manual mechanical inspection with an automated system using optical sensors (cameras), LIDAR, and RFID technology. The autonomous ground vehicle uses these non-contact sensing methods to detect and locate malfunctioning vehicles, substituting human operators and eliminating the need for system shutdown
2Measurement precision
If the system is shut down for manual inspection, then accurate location of malfunctioning vehicles can be determined, but operational efficiency decreases
Solution Approach 1:
The autonomous ground vehicle performs self-navigation and self-inspection tasks using onboard sensors and processors. It autonomously travels to malfunctioning vehicles, captures images, reads RFID tags for identification, and communicates findings back to the control system without human intervention, enabling continuous system operation while maintaining accurate location determination
Solution Approach 2:
The system continuously monitors vehicle status and pre-positions the autonomous ground vehicle for rapid response. When a malfunction is detected, the autonomous vehicle is already prepared and can immediately navigate to the malfunctioning vehicle, reducing inspection time while maintaining accurate location determination
3Measurement precision
If visual inspection from above is attempted in large systems with low ceiling heights, then inspection can be performed, but the framework structure obstructs the view
Solution Approach 1:
The patent transitions from top-down vertical inspection (obstructed by the framework structure) to horizontal ground-level inspection. The autonomous ground vehicle operates on the same level as the malfunctioning vehicles, navigating around framework columns and providing unobstructed close-up views, effectively changing the inspection dimension from above to at-level
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A method of monitoring an automated storage and retrieval system (1) utilizing a flying drone (400) to locate and inspect anomalies in the operation of the system.