Floor Conveyor Sensing Layout for Multi-Side Stop Zone Control
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Solution Overview
Problem
Existing floor conveyor systems face complexity and operational issues due to the need for multiple sensors, leading to potential human error and mismatched sensor data, which complicates safe and efficient object detection and collision avoidance.
Innovation Solution
A floor conveyor system with a single sensor device mounted at an angle, capable of detecting objects on multiple sides, featuring a stop section with adjustable configurations to optimize operator safety and efficiency, including a wedge shape for closer operator access and a broader stop area for safety, and the ability to steer away or maintain distance from objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sensor devices are used to detect objects on multiple sides of the floor conveyor, then detection coverage and safety are improved, but device complexity and potential for human error increase
Solution Approach 1:
A single sensor device is designed to perform multiple functions by detecting objects on multiple sides of the floor conveyor simultaneously. The sensor device includes a first sensor for detecting objects in a first direction and a second sensor for detecting objects in a second direction, allowing one device to replace what would traditionally require multiple separate sensors.
Solution Approach 2:
Multiple sensing functions are merged into a single sensor device structure. The first sensor and second sensor are integrated into one device housing, with both sensors working together to provide comprehensive object detection coverage on multiple sides of the conveyor, reducing the total number of separate components needed.
2Ease of operation
If the stop section has a wedge shape narrowing away from the conveyor, then operator access for order picking is improved, but detection coverage on the opposite side is reduced
Solution Approach 1:
The stop section is designed with different geometries on different sides to match local operational requirements. On the operator side, the stop section has a wedge shape that narrows away from the conveyor, creating more workspace for order picking. On the opposite side, the stop section maintains a constant width to ensure adequate detection coverage and safety margins.
Solution Approach 2:
The stop section employs asymmetric design where the first stop section (operator side) has a wedge shape while the second stop section (opposite side) has a constant width. This asymmetric configuration allows the system to optimize for both operator accessibility and safety/detection coverage simultaneously.
Data Source
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AI summary
A floor conveyor (1), a control unit (3) and a sensor device (2), wherein the control unit (3) is operable to control the travel functions of the floor conveyor (1), wherein the sensor device (2) is arranged to be able to provide the control unit (3) with sensor data, wherein the sensor device (2) is arranged such that it can detect objects in a plane (4), wherein the plane (4) is extending along the a first side (13a) of the floor conveyor (1), wherein the plane (4) comprises a stop section (30), wherein the floor conveyor (1) is arranged such that if an object is detected in the stop section (30) the floor conveyor is stopped by control of the travel function from the control unit (3) upon receipt by it of a sensor data indicating the object being positioned in the stop section (30), wherein the stop section (30) is also extending along a section of a second side (13b) of the floor conveyor, preferably the second side (13b) is essentially perpendicular to the first side (13a). The invention also relates to a method for operating the floor conveyor and a computer executable software.