Gravity Feed Rack Sensing for Flexible Stock Recording
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Solution Overview
Problem
Existing flow rack units require laborious adaptation of sensor technology when changes occur in shelf layout or storage material configuration, making it difficult and costly to record and manage stock levels efficiently.
Innovation Solution
A control system for flow rack units that uses a single distance sensor per shelf to measure the distance to the rearmost storage material unit, allowing for software-based adaptation to changes in configuration without the need for additional sensors, and includes occupancy and loading sensors connected via a data line for efficient stock management and worker guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is assigned to each storage material unit position on every shelf, then the stock of storage material can be recorded, but the number of sensors required becomes very large and the system becomes complex and costly
Solution Approach 1:
Multiple sensors that would traditionally be assigned to individual storage positions are merged into a single sensor per shelf. The sensor measures the overall distance from the storage side to the rearmost storage material unit, and the control unit calculates the number of units based on this single measurement, thereby reducing sensor quantity while maintaining stock recording capability
Solution Approach 2:
The control unit acts as an intermediary that processes the single distance measurement and converts it into stock quantity information. By storing length information about individual storage material units, the control unit mediates between the physical measurement and the logical inventory data, eliminating the need for multiple sensors
2Adaptability or versatility
If sensor technology is adapted to changed shelf layouts, then the system can accommodate process changes, but the adaptation process becomes laborious and time-consuming
Solution Approach 1:
The system transitions from a static sensor configuration to a dynamic one where the control unit can adapt to different shelf layouts through software reconfiguration. The control program can be modified to reflect changed compartment configurations without physical sensor repositioning, enabling flexible adaptation to process changes
Solution Approach 2:
The patent replaces the mechanical/physical sensor positioning system with a software-based configuration system. Instead of physically moving or reassigning sensors when layouts change, the control program is updated with new length information and compartment definitions, substituting physical reconfiguration with digital adaptation
3Measurement precision
If multiple sensors are used per shelf to track individual storage material units, then accurate stock levels can be monitored, but the cost of the sensor system increases significantly
Solution Approach 1:
The patent extracts the essential measurement function from multiple individual sensors and concentrates it into a single sensor per shelf. By taking out only the necessary distance measurement and processing it through the control unit with stored length data, the system achieves accurate stock monitoring with minimal sensor quantity
Solution Approach 2:
The control unit uses stored length information (a digital copy of physical unit dimensions) to calculate stock quantities from the single sensor measurement. This copying approach allows the system to infer individual unit positions and counts without physically sensing each unit, reducing sensor requirements while maintaining accuracy
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 simple and cost-effective recording of storage material stock levels, reduces the need for sensor reconfiguration during layout changes, and ensures accurate placement and management of storage material units, improving operational efficiency and reducing labor costs.
Implementation Method 1
The occupancy sensors can be designed to determine the distances optically, for example according to the light travel principle (time-of-flight or ToF principle). The occupancy sensors can be designed to emit an optical measurement signal into the measurement area and to receive a portion of the measurement signal reflected by the rearmost storage material unit in order to determine the distance.
Data Source
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AI summary
A flow rack unit for providing storage material units comprises at least two rack bays and a control system. Each rack bay has a retrieval side and a storage side opposite the retrieval side and is designed to provide the storage material units sequentially on a single bay level, starting from the retrieval side and moving towards the storage side. Each rack bay is assigned a sensor array of the control system. The sensor arrays are located on the storage side of their assigned rack bay and are connected to a control unit of the control system via a common data line. Each sensor array includes an occupancy sensor configured as a distance sensor.Each occupancy sensor has a measuring range oriented from the storage side of the assigned shelf compartment towards the retrieval side of the assigned shelf compartment to measure the distance to the furthest storage unit stored in the assigned shelf compartment and closest to the occupancy sensor. Each occupancy sensor is configured to transmit distance data representing the measured distance to the control unit via the data line to record the number of storage units stored in the shelf compartments. Each sensor array is configured to detect the insertion of a storage unit to be inserted at the storage side of the assigned shelf compartment and to transmit loading sensor data indicating the insertion to the control unit via the data line.