Improved sensor system for a display rack
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Solution Overview
Problem
Existing sensor systems for display racks face challenges in accurately determining object type, location, and weight due to limitations in weight distribution, accuracy deterioration over time, and trade-offs between weight and pattern determination, especially in high-throughput environments like supermarkets.
Innovation Solution
A system utilizing sensor mats with a lattice of load sensors to measure binary load status, allowing for accurate determination of object weight and location by measuring changes in total weight and binary load status before and after object addition or removal, without compromising object support shape accuracy, and using simpler sensor mats to reduce accuracy deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a compressive material is placed on top of the sensor surface to improve weight measurement, then weight measurement accuracy is improved, but object pattern determination deteriorates due to blurring
Solution Approach 1:
The system divides the measurement task into two separate sensor systems: one dedicated to weight measurement (with compressive material) and another dedicated to pattern detection (without compressive material). This segmentation allows each sensor type to optimize for its specific function without compromising the other.
Solution Approach 2:
The system introduces an intermediary processing layer that combines data from both sensor types. The processor integrates weight measurements from the compressive sensor array with pattern information from the non-compressive sensor array, reconciling the trade-off between these two measurement goals.
2Adaptability or versatility
If a matrix of sensors is used for both pattern and weight determination, then both functions can be performed, but weight accuracy deteriorates over time during the sensor life cycle
Solution Approach 1:
The system separates weight measurement and pattern detection into distinct sensor arrays with different physical properties. The weight measurement sensors are designed specifically for stable long-term weight detection, while the pattern sensors are optimized for spatial resolution, eliminating the degradation issue that affects multi-functional sensors.
Solution Approach 2:
The system creates two separate sensor systems that both detect load information but with different optimizations. One system copies the load information for weight measurement purposes, while the other copies it for pattern recognition, allowing each to be optimized independently for its specific measurement type and longevity requirements.
3Ease of manufacture
If simpler sensor mats are used to reduce cost and improve longevity, then manufacturing cost and durability are improved, but measurement precision and granularity deteriorate
Solution Approach 1:
The system segments the measurement requirements into two independent sensor types, each optimized for its specific function. This allows the use of simpler, more durable sensors for weight measurement while employing more sophisticated sensors for pattern detection, achieving overall system precision without requiring all sensors to be complex and expensive.
Solution Approach 2:
The system creates a multi-functional sensor array where different sensor types work together to provide both weight and pattern information. Each sensor type maintains its specialized function, allowing simpler sensors to be used where appropriate while maintaining overall measurement precision through the combination of multiple sensor types.
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
The system provides accurate and reliable determination of object weight, location, and support shape, improving accuracy and longevity of sensor mats while eliminating trade-offs, enabling effective triggering of replenishment and monitoring in dynamic environments.
Implementation Method 1
Each shelf comprises a sensor mat comprising a lattice of load sensors. The base is configured for measuring a total weight... binary load status of multiple load sensors of a sensor mat... whether a sensor of the lattice at least in part supports an object or not
Data Source
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Figure 2
AI summary
A display rack comprises shelves and a base. Each shelf comprises a sensor mat comprising a lattice of load sensors. The base is configured for measuring a total weight, which includes weights of any objects positioned on the shelves. The system is configured for determining object addition or removal event data based on in time corresponding changes of: total weight measured at the base; and binary load status of multiple load sensors of a sensor mat of the display rack. A binary load status of a load sensor indicates whether the load sensor at least in part supports an object or not. The event data comprises: an object weight based on said change of total weight measured at the base; and an object support shape and an object location both based on said change of binary load status of multiple load sensors of said sensor mat of the display rack.