Grid Survey Module for Rail Level Deviation Mapping
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Solution Overview
Problem
Automated storage and retrieval systems face issues due to level deviations and unevenness in the grid, leading to potential damage to containers, columns, and handling vehicles, as well as operational inefficiencies and safety hazards.
Innovation Solution
Implementing a method and system using orientation sensors, such as IMUs and precise inclination sensors, on container handling vehicles to measure pitch and roll, calculate height differences, and generate maps to identify and adjust level deviations in the grid, ensuring the rail system remains level and safe for operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the grid structure is used for automated storage and retrieval, then storage capacity and automation are improved, but level deviations cause damage to containers and vehicles
Solution Approach 1:
The system performs preliminary measurement of level deviations using orientation sensors before containers and vehicles are affected. By detecting pitch and roll angles in advance, the system can identify problematic grid cells and alert operators to take preventive actions, avoiding damage to containers and vehicles before it occurs.
Solution Approach 2:
The system continuously monitors the grid structure using orientation sensors mounted on moving vehicles, creating a feedback loop that provides real-time information about level deviations. This feedback enables the system to track changes in grid integrity over time and respond appropriately to maintain safety and prevent damage.
2Device complexity
If the grid structure operates without continuous monitoring, then device complexity is reduced, but level deviations lead to operational inefficiencies and safety hazards
Solution Approach 1:
The orientation sensors serve multiple functions: they measure pitch and roll angles for level detection, track vehicle position and orientation, and provide data for both safety monitoring and operational optimization. This multi-functionality reduces the need for separate monitoring systems while enhancing reliability.
Solution Approach 2:
The moving vehicles in the automated system carry their own orientation sensors, making them self-monitoring units. As vehicles move throughout the grid, they autonomously collect data about level deviations, eliminating the need for a separate stationary monitoring infrastructure and reducing overall system complexity while maintaining high reliability.
3Measurement precision
If orientation sensors are installed on vehicles to measure level deviations, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The vehicles in the automated storage and retrieval system are equipped with orientation sensors that utilize the vehicles' own motion and positioning capabilities to measure grid level deviations. This approach leverages existing vehicle functions for measurement purposes, avoiding the need for additional dedicated measurement equipment and reducing overall device complexity while maintaining high measurement 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
Prevents damage to containers and vehicles, maintains system efficiency, and ensures safe operation by continuously monitoring and adjusting the grid for level deviations, reducing the risk of accidents and prolonging system uptime.
Implementation Method 1
The container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of the sensor in a three-dimensional cartesian reference system
Data Source
AI summary
A method of measuring level deviation in an automated storage and retrieval system, wherein the system includes rail system, at least one container handling vehicle, and a central control unit. The rail system includes a first set of parallel rails arranged to guide movement of a container handling vehicle in a first direction across the top of a frame structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicle in a second direction which is perpendicular to the first direction. The first and second sets of parallel rails divide the rail system into a plurality of grid cells. The at least one container handling vehicle is configured to operate on the rail system. The at least one container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of the sensor in a three-dimensional cartesian reference system. The central control unit is configured to receive, transmit, and process data signals of the container handling vehicle and to receive and process data signals of the sensor. The method includes arranging the container handling vehicle in a predetermined position on the grid, transmitting a data signal from the central control unit to the container handling vehicle commanding the container handling vehicle to move a distance in one direction along the grid, and measuring at predetermined intervals, using the orientation sensor, at least one orientation parameter to produce orientation measurements that are indicative of the container handling vehicle's orientation within the three-dimensional cartesian reference system. The method further includes transmitting data concerning the orientation measurements to the central control unit, and processing the orientation measurements using the central control unit in order to identify portions of the rail system that deviate from predetermined values.