Elevator Platform Positioning with Optical Rail Detection
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Solution Overview
Problem
Existing vertical storage systems face challenges in accurately positioning the elevator platform relative to the tray storage locations due to factors like sagging of tensioned members or deformation of rails.
Innovation Solution
A storage system with a servomotor-operated elevator platform and optical sensors that dynamically adjust the platform's position by moving at different speeds and detecting rail sidewalls using laser sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a tensioned member (belt or chain) is used to move the elevator platform, then the platform can be moved vertically between storage locations, but positioning accuracy deteriorates due to sagging of the tensioned member
Solution Approach 1:
The system employs optical sensors that detect the position of the elevator platform relative to the rails by sensing the reflection of light from the rail sidewalls. This feedback mechanism allows the control system to identify the actual position of the platform and compensate for positioning errors caused by tensioned member sagging, thereby maintaining accurate positioning despite using a belt or chain drive system
Solution Approach 2:
The patent replaces purely mechanical positioning methods with an optical sensing system. Instead of relying solely on mechanical encoders or position sensors integrated into the tensioned member system, the invention uses optical sensors to detect platform position by measuring the reflection of light from rail sidewalls, substituting mechanical measurement with optical measurement to achieve higher positioning accuracy
2Measurement precision
If the control system accounts for sagging of the tensioned member, then positioning accuracy improves, but device complexity increases
Solution Approach 1:
The optical sensors are mounted on the elevator platform itself, allowing the system to self-measure its position relative to the rails. The platform uses its own structure to sense its position by detecting the reflection from rail sidewalls, eliminating the need for external complex measurement systems or multiple sensors distributed throughout the rack structure
3Measurement precision
If optical sensors are used to detect rail sidewalls, then positioning precision improves, but device complexity increases due to additional sensors
Solution Approach 1:
The optical sensors serve multiple functions: they detect the position of the platform relative to the rails, verify proper tray placement by detecting rail sidewalls, and provide feedback for the control system to adjust positioning. This multi-functionality reduces the need for separate sensors for each function, thereby limiting the increase in device complexity while achieving high positioning precision
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
This solution enables precise retrieval and storage of trays by accounting for positional variations, ensuring accurate delivery within fractions of a millimeter and allowing for self-diagnosis of potential issues.
Implementation Method 1
a plurality of optical sensors arranged on the platform to detect the sidewalls of the rails of the storage rack
Data Source
AI summary
A storage system comprises a rack defining a plurality of storage locations arranged one above the other, trays removably stored at the storage locations, and an elevator configured for moving a selected tray between its assigned storage location and a retrieval space below the storage locations. The storage locations are formed by pairs of horizontally opposite spaced apart rails with inwardly projecting sidewalls on which a tray can be rested. The elevator comprises a platform configured to carry and transfer the trays to and from the rack, and a drive system configured to move the platform that includes a servomotor. The platform carries optical sensors used cooperatively with the servomotor to detect a selected storage location of a tray to be stored or retrieved. Upon input of a selected storage location, the platform is displaced initially at a high speed until reaching a vertically offset position relative to the selected storage position detected using the servomotor, and therefrom at a low speed until sidewalls of the rails of the selected storage location are detected using the optical sensors.