Automated Yard Audit Using LIDAR Virtual Representation
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Solution Overview
Problem
Manual audits in fulfillment centers are inefficient, time-consuming, and pose safety risks to associates, as they require frequent physical checks of yard slips and assets, which can lead to inaccurate data and increased exposure to safety hazards.
Innovation Solution
An automated yard audit system utilizing Light Detection and Ranging (LIDAR) sensors to create a virtual representation of the fulfillment yard, track asset movements, and provide real-time audit information, reducing the need for manual checks and improving safety by allowing remote monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual audits are performed periodically throughout the day, then the health of the yard and tracking of yard equipment can be maintained, but associates spend a large amount of time in the actual fulfillment yard and are exposed to safety risks
Solution Approach 1:
The patent replaces the mechanical manual auditing system with an automated optical sensing system using LIDAR sensors. The LIDAR sensors automatically scan and capture data about yard slips, trailers, and equipment conditions without requiring associates to physically enter the fulfillment yard, thereby eliminating safety risks while maintaining reliable monitoring of yard health and equipment tracking.
Solution Approach 2:
The patent creates a virtual digital representation (digital twin) of the fulfillment yard that mirrors the physical yard's state in real-time. This virtual model allows associates to monitor yard conditions, equipment status, and potential hazards remotely through a user interface, eliminating the need for physical presence in the yard while maintaining comprehensive oversight.
2Measurement precision
If associates walk through the yard to manually check the state of each yard slip, then the state of yard slips can be verified against the management system, but the process is inefficient and time consuming
Solution Approach 1:
The patent replaces manual visual inspection with automated LIDAR sensing technology. The LIDAR sensors emit laser pulses and measure the reflected light to precisely detect the presence, position, and condition of trailers and equipment at each yard slip. This automated measurement system verifies yard slip states with high precision simultaneously across multiple locations, eliminating the time-consuming sequential manual walking process.
Solution Approach 2:
The patent implements continuous real-time monitoring of the fulfillment yard through continuously operating LIDAR sensors that constantly scan and update the virtual representation of the yard. This continuous automated auditing process eliminates the need for periodic manual audits, maintaining precise verification of all yard slips without interruption or time loss.
3Ease of operation
If associates perform directed moves of assets and inspect damages during manual audits, then yard operations can be managed, but associates have an increased chance of encountering a yard incident
Solution Approach 1:
The patent creates a virtual representation of the fulfillment yard that includes real-time data about asset positions, movements, and conditions. Associates can perform directed moves of assets and inspect damages by interacting with this virtual model through a user interface, completely eliminating the need to physically enter the fulfillment yard and exposing zero associates to yard incidents while maintaining full operational capability.
4Reliability
If manual audits are performed to keep track of yard equipment, then equipment health can be monitored, but the process is time consuming and reduces productivity
Solution Approach 1:
The patent implements continuous automated tracking of yard equipment using LIDAR sensors that constantly monitor the position, movement, and condition of trailers and other assets in real-time. This continuous monitoring maintains reliable equipment tracking without the time loss associated with periodic manual audits, as the system operates uninterrupted and provides up-to-date equipment status information instantly.
Solution Approach 2:
The patent replaces the mechanical manual equipment tracking process with automated optical sensing and digital data processing. The LIDAR sensors automatically detect and track equipment positions and conditions, and the system continuously updates the virtual representation and alerts associates to any equipment issues, eliminating the time-consuming manual walking and checking process while maintaining reliable tracking.
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 significantly reduces the time spent on audits, enhances data accuracy, and minimizes safety risks by enabling real-time monitoring and management of yard operations, improving the overall efficiency and safety of fulfillment center operations.
Implementation Method 1
An automated yard audit system utilizing Light Detection and Ranging (LIDAR) sensors to create a virtual representation of the fulfillment yard
Data Source
AI summary
An automated yard audit system is provided. The automated yard audit system includes one or more light detection and ranging (LIDAR) sensors, which are each configured to scan at least a portion of a fulfillment yard, and a controller. The controller is configured to receive scanning data of the yard from each of the LIDAR sensors and generate a virtual representation of the fulfillment yard based on the scanning data. The controller is also configured to identify one or more objects in the fulfillment yard, track movement of the one or more objects in the fulfillment yard, perform an audit of the fulfillment yard, and determine capacity information of the fulfillment yard, based on the virtual representation.