Container Handler Guide Pin Sensor for Automated Storage
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Solution Overview
Problem
Existing container handling vehicles in automated storage and retrieval systems face inefficiencies due to mechanical wear from physical contact sensors and limited precision in positioning, leading to potential collisions and reduced operational speed.
Innovation Solution
The implementation of non-contact sensors, such as capacitive, ultra-sonic, or optical sensors, integrated into guide pins to accurately sense the position of storage containers and top structures, allowing for controlled and efficient vertical movement of the lifting frame, reducing mechanical wear and enhancing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical contact sensors are used to detect storage container position, then the sensing function is achieved, but mechanical wear occurs and reliability decreases
Solution Approach 1:
The patent replaces physical contact sensors with non-contact sensors (optical, capacitive, or ultra-sonic sensors) that detect storage container position without mechanical contact. This substitution eliminates mechanical wear on both the sensor and the storage container while maintaining the position detection function, thereby improving reliability and reducing harmful mechanical wear factors.
2Measurement precision
If physical contact sensors are used for position detection, then positioning information is obtained, but precision is limited and potential collisions occur
Solution Approach 1:
The patent employs non-contact sensors (optical, capacitive, or ultra-sonic) to detect the position of storage containers with higher precision than mechanical contact sensors. These sensors can detect position changes before physical contact occurs, enabling the control system to predict contact points and adjust the lifting frame position accordingly, thereby preventing collisions and improving both measurement precision and reliability.
Solution Approach 2:
The patent implements preliminary detection of storage container position using non-contact sensors before the lifting frame reaches the container. The control system uses this advance information to predict contact points and pre-adjust the lifting frame position, speed, and deceleration margins, thereby preventing collisions and improving positioning precision before the actual contact occurs.
3Productivity
If operational speed is increased to improve productivity, then handling efficiency increases, but collision risk increases and precision decreases
Solution Approach 1:
The patent employs non-contact sensors to continuously monitor the position of storage containers and the lifting frame in real-time. The control system uses this feedback information to dynamically adjust the lifting frame speed, position, and deceleration margins during operation. This closed-loop control enables the system to maintain high productivity while preventing collisions by continuously adapting to actual container positions, thereby resolving the contradiction between speed and safety.
Solution Approach 2:
The patent uses non-contact sensors to detect storage container positions in advance before the lifting frame reaches them. The control system calculates predicted contact points and pre-adjusts the lifting frame speed and deceleration margins accordingly. This preliminary action allows the system to operate at higher speeds while maintaining precision and collision prevention, as the necessary adjustments are made before the potential collision zone is reached.
4Reliability
If deceleration margin is increased to prevent collisions, then safety improves, but handling time increases and productivity decreases
Solution Approach 1:
The patent uses non-contact sensors to detect storage container positions in advance, allowing the control system to calculate predicted contact points and pre-determine the optimal deceleration margins. By performing this calculation beforehand based on real-time position data, the system can apply the minimum necessary deceleration to prevent collisions, avoiding excessive deceleration that would increase handling time, thereby balancing safety with productivity.
Solution Approach 2:
The patent implements continuous feedback from non-contact sensors monitoring the actual positions of storage containers and the lifting frame. The control system uses this real-time feedback to dynamically adjust deceleration margins during operation, applying only the necessary deceleration to prevent collisions based on actual conditions. This adaptive approach prevents excessive deceleration and minimizes handling time while maintaining collision prevention, resolving the contradiction between safety and productivity.
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 faster and more precise handling of storage containers by predicting contact points, reducing deceleration margins, and increasing operational efficiency while minimizing mechanical wear on sensors.
Implementation Method 1
The first sensor is a capacitive sensor
Implementation Method 2
The first sensor is a capacitive sensor, an ultra-sonic sensor or an optical sensor
Implementation Method 3
The first sensor is a capacitive sensor, an ultra-sonic sensor or an optical sensor
Data Source
AI summary
A container handler handles a storage container in a column of a frame structure of an automated storage and retrieval system. The container handler includes a lifting frame, a first guide pin, and a gripper element. The lifting frame is arranged for vertical movement within the column of the frame structure. The first guide pin protrudes downwardly from the lifting frame for guiding the lifting frame vertically within the column of the frame structure relative to the storage container. The gripper element protrudes downwardly from the lifting frame for gripping the storage container. The first guide pin includes a first sensor for sensing the position of the lifting frame relative to the storage container. The container handler includes a control system provided in communication with the first sensor. The control system is controlling the vertical movement of the lifting frame and is controlling the gripper element based on a signal received from the first sensor. The control system is configured to start the movement of the gripper element before the lifting frame is in physical contact with the storage container based on the signal received from the first sensor.