Grid Rail Survey Using Vehicle IMU for Level Deviation Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Automated storage and retrieval systems face issues due to uneven grid levels, leading to potential damage to containers, columns, and handling vehicles, as well as operational inefficiencies and safety hazards from height differences and wear and tear.

Innovation Solution

Implement a method using container handling vehicles equipped with orientation sensors to measure pitch and roll, calculating skewness and height differences in grid cells, generating maps to identify and adjust deviations, and maintaining a level rail system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If automated storage and retrieval systems operate without continuous level monitoring, then operational simplicity is maintained, but grid level deviations cause damage to containers, columns, and handling vehicles

Engineering Contradiction:

Improvesystem safetyVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The container handling vehicle performs dual functions: container manipulation and grid surveying. The vehicle uses its own orientation sensors (inertial measurement units) to measure grid cell levels autonomously during normal operations, eliminating the need for separate monitoring equipment while enhancing system safety

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The container handling vehicle is designed to perform multiple functions: container picking, placing, transportation, and grid level surveying. This multi-functionality reduces overall system complexity by consolidating monitoring capabilities into existing operational assets

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If grid level deviations are not corrected, then operational efficiency is maintained, but height differences cause wear and tear and operational inefficiencies

Engineering Contradiction:

Improveoperational efficiencyVSAvoidwear and tear

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system continuously collects orientation data from container handling vehicles, processes it to calculate grid cell level deviations, and provides feedback for corrective action. This feedback loop enables timely detection and correction of level deviations before they cause significant wear or operational problems

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs grid surveys during normal container handling operations, proactively identifying level deviations before they escalate into harmful conditions. By monitoring continuously during routine operations, the system can address issues before they affect productivity

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If orientation sensors are installed on container handling vehicles, then grid level measurement precision is improved, but vehicle and system complexity increases

Engineering Contradiction:

Improvelevel deviation detection accuracyVSAvoidvehicle system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The container handling vehicle uses its own inertial measurement unit (IMU) and orientation sensors to autonomously measure grid cell levels. The vehicle's existing navigation and control systems are leveraged for data collection, minimizing additional complexity while achieving precise measurements

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The orientation sensing capabilities are merged with the vehicle's existing navigation and control systems. The same sensors used for vehicle positioning and container manipulation are also utilized for grid level measurement, reducing overall system complexity while maintaining measurement precision

Inventive Principle:

Principle #5Merging (Combining)

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

Ensures safe and efficient operation by continuously monitoring and correcting grid level deviations, preventing damage and enhancing system reliability.

Implementation Method 1

measuring pitch and roll, calculating skewness and height differences in grid cells

Methodology Applied

Scientific EffectPitch and roll measurement:

Data Source

PatentUS20260103341A1Grid survey module

Publication Date: 2026.04.16 AUTOSTORE TECH AS

AI summary

Measuring level deviation in an automated storage and retrieval system, the system having a rail system, container handling vehicle, and central control unit. The rail system includes first parallel rails to guide movement of a container handling vehicle in a first direction across the top of a frame structure, and second parallel rails perpendicular to the first rails to guide movement of the vehicle in a second direction perpendicular to the first. The first and second parallel rails divide the rail system into grid cells. The vehicle operates on the rail system. The vehicle has at least one orientation sensor to measure at least one orientation parameter in a 3D Cartesian reference system. The control unit can process data signals of the vehicle and the sensor. Method includes arranging the vehicle in a position on the grid, transmitting a signal from the control unit to the vehicle to move a distance in one direction, measuring at intervals, using the sensor, a parameter to produce orientation measurements of the vehicle's orientation within the reference system, transmitting and processing data concerning the orientation to the control unit to identify deviating rail system portions.