Drone Inspection of Storage Grid Robots Under Low Ceilings
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Solution Overview
Problem
Existing automated storage and retrieval systems face challenges in accurately locating and visually inspecting malfunctioning autonomous container-handling vehicles, particularly in large systems with low ceiling heights, often requiring costly and dangerous manual inspections.
Innovation Solution
Employing a flying drone to navigate above the framework structure, using optical sensors and predefined navigation patterns or communication with the control system to locate and visually inspect malfunctioning vehicles, with the option for human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to locate malfunctioning vehicles, then inspection can be performed, but safety risks increase and operational costs rise
Solution Approach 1:
The patent introduces an intermediary device (drone with camera and sensors) to perform the inspection task between the malfunctioning vehicle and human operators. The drone autonomously navigates to the malfunctioning vehicle's location, captures images and data, and transmits them to the control system, eliminating the need for human operators to physically approach hazardous areas while maintaining high location accuracy through GPS coordination and visual recognition
2Reliability
If the system shuts down to inspect malfunctioning vehicles, then inspection can be performed, but productivity decreases
Solution Approach 1:
The system performs self-inspection through autonomous drones that are automatically deployed when malfunctioning vehicles are detected by the control system. The drones independently navigate, inspect, and report back without requiring system shutdown or human intervention, allowing the storage system to continue operating while maintaining safety through continuous monitoring
Solution Approach 2:
The patent replaces the mechanical approach of shutting down the system for inspection with an automated aerial inspection system. The drone-based inspection mechanism substitutes for traditional ground-based manual inspection methods, enabling continuous system operation while maintaining safety through remote, automated monitoring capabilities
3Object-affected harmful factors
If aerial inspection is implemented, then safety and productivity are improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional drone system that integrates navigation (GPS), visual inspection (camera), data transmission (communication module), and autonomous control capabilities into a single device. The control system also serves multiple functions including detecting malfunctioning vehicles, coordinating drone deployment, receiving inspection data, and managing system operations, thereby reducing the need for separate specialized systems
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 precise localization and visual inspection of malfunctioning vehicles without system shutdown, enhancing safety and reducing manual intervention costs.
Implementation Method 1
using optical sensors and predefined navigation patterns or communication with the control system to locate and visually inspect malfunctioning vehicles
Data Source
AI summary
An automated storage and retrieval system includes a storage grid provided by a framework structure arranged in a building under a ceiling. The framework structure includes a rail system arranged at an upper level of the framework structure. The rail system includes a first set of parallel rails arranged in a horizontal plane and extending in a first direction, and a second set of parallel rails arranged in the horizontal plane and extending in a second direction which is orthogonal to the first direction. The first and second sets of rails form a grid pattern in the horizontal plane including a plurality of adjacent access openings/grid cells. The storage grid defines a plurality of storage columns. Each storage column being arranged to store a respective stack of storage containers. The storage columns are located beneath the rail system. Each storage column is located vertically below a respective access opening/grid cell. Container handling vehicles operate on the rail system to collect and return storage containers to and from storage columns. A control system monitors and controls the automated grid storage and retrieval system. A method for monitoring the automated storage and retrieval system includes: launching a flying drone equipped with a camera to an altitude in an airspace located between an upper surface of framework structure and the ceiling or roof obstacle beneath the ceiling, navigating the drone to a suspected location of an anomaly in the system or other aspect of the system in need of inspection, using the drone to locate the anomaly or aspect of the system in need of inspection, and performing a visual inspection of the anomaly or aspect of the system in need of inspection using the camera of the flying drone. The control system includes an exception handler module responsible for identifying and attempting to correct anomalies in the operation of the storage system, and a flight control module responsible for controlling the flight of the drone. The flight control module directs the flight of the drone in response to instructions received from the exception handler module.