Dynamic Storage Rack Checking Units Reduce Cabling Complexity
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Solution Overview
Problem
Existing dynamic storage rack systems for logistics and manufacturing are complex, inflexible, and have high cabling complexity, leading to errors during installation and operation, and require a wide variety of sensors and displays that are difficult to connect and adapt to different configurations.
Innovation Solution
A dynamic storage rack unit with compartment checking units that supply energy and transmit data for sensors, a storage rack checking unit that manages multiple compartment checking units, and a central checking unit that oversees the system, allowing for flexible adaptation to various configurations and simplifying cabling by using standardized modules and wireless communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a wide variety of sensors and displays are provided for different storage rack configurations, then the system can monitor and control various compartment arrangements, but the cabling complexity increases and installation errors occur more frequently
Solution Approach 1:
The patent implements a universal checking unit design that can monitor multiple storage rack compartments through a standardized interface. The checking unit is configured to work with different sensor types (optical, magnetic, mechanical) and can adapt to various compartment arrangements without requiring dedicated cabling for each configuration, thus reducing overall system complexity while maintaining versatility
Solution Approach 2:
The system divides the monitoring function into independent checking units that can be individually configured and connected. Each checking unit handles specific compartments autonomously, allowing modular installation and reducing the need for complex centralized cabling. This segmentation enables flexible system expansion without proportionally increasing cabling complexity
2Reliability
If numerous sensors and displays are installed in the storage rack system, then comprehensive monitoring capability is achieved, but the system becomes more error-prone during installation and operation
Solution Approach 1:
The patent combines multiple sensing functions into integrated checking units that perform both detection and evaluation in a single component. This merging reduces the total number of separate elements in the system, thereby decreasing installation complexity and potential error sources while maintaining comprehensive monitoring coverage across all storage compartments
Solution Approach 2:
The system incorporates feedback mechanisms where checking units continuously monitor compartment status and provide real-time information to the control system. This automated feedback loop reduces manual intervention requirements, minimizes human error in operation, and enhances overall system reliability by immediately detecting and reporting abnormal conditions
3Ease of manufacture
If the storage rack system is designed with fixed configuration, then installation is simpler, but the system cannot be easily adapted to different manufacturing requirements
Solution Approach 1:
The patent implements a dynamic configuration system where checking units can be programmatically assigned to different compartment arrangements. The system allows runtime reconfiguration of monitoring parameters and sensor assignments without physical hardware changes, enabling the same base installation to adapt to various manufacturing requirements while maintaining installation simplicity
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
The solution reduces cabling complexity, enhances error tolerance, and allows for easy expansion or retrofitting of existing systems, enabling efficient monitoring and control of storage rack compartments with reduced effort and improved flexibility.
Implementation Method 1
the checking units each being in the form of energy and data transmission units for supplying the respective sensors of the respective storage rack compartment with electrical energy
Data Source
AI summary
The invention proposes a dynamic storage rack unit for providing material in logistics and/or manufacturing processes, having a plurality of storage rack compartments (3) inclined in the longitudinal direction, each storage rack compartment (3) being designed to accommodate a plurality of material containers (4) arranged beside one another in the longitudinal direction, storage rack compartments (3) each having a plurality of sensors (5) for monitoring the filling level of the respective storage rack compartment (3), a distance (A) which corresponds substantially to the length of the material containers (4) to be accommodated in the storage rack compartment (3) being provided in the longitudinal direction between sensors (5) of the respective storage rack compartment (3), storage rack compartments (3) each having at least one state display apparatus (10) for displaying the state and/or filling level of the respective storage rack compartment (3), which unit at least partially improves the disadvantages of the prior art. According to the invention, this is achieved by virtue of the fact that storage rack compartments (3) each comprise at least one compartment checking unit (6) for checking the respective sensors (5) of the respective storage rack compartment (3), the compartment checking units (6) each being in the form of energy and data transmission units (6) for supplying the respective sensors (5) of the respective storage rack compartment (3) with electrical energy and for acquiring, receiving and transmitting sensor data from the respective sensors (5) of the respective storage rack compartment (3), at least one storage rack checking unit (7) for checking a plurality of compartment checking units (6) of the storage rack compartments (3) being provided, the at least one storage rack checking unit (7) being designed to supply the plurality of compartment checking units (6) of the respective storage rack compartments (3) with electrical energy and to acquire, receive and transmit data from the plurality of compartment checking units (6) of the respective storage rack compartments (3), at least one central checking unit (11, 12, 13) for checking the at least one storage rack checking unit (7) being provided, the central checking unit (11, 12, 13) being designed to acquire, receive and transmit data from the at least one storage rack checking unit (7).