MEMS Sensor Pallet for Load Dynamics Measurement
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Solution Overview
Problem
Current systems for measuring physical quantities acting on palletized loads during transport are not precise and can alter the load's dynamics, and existing solutions are vulnerable to damage and do not accurately measure kinematic and environmental stresses in real-time.
Innovation Solution
A measuring system comprising a supporting frame with two detecting modules and a processing module that uses MEMS sensors to measure kinematic and environmental physical quantities without altering the load's weight or dynamics, featuring separate data acquisition chains for kinematic and environmental data to ensure precise and accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are fixed outside the load to transmit data related to stresses acting on the load during transport, then measurement is possible, but the measurement is not precise and complete as sensors modify the structure, weight and dynamic behaviour of the load
Solution Approach 1:
The patent introduces a measuring system that acts as an intermediary between the load and the measurement process. The system includes sensors positioned to measure physical quantities (acceleration, temperature, humidity, pressure) without directly fixing to the load, and a processing unit that receives and processes data from these sensors. This intermediary approach allows measurement while minimizing interference with the load's natural behavior during transport.
Solution Approach 2:
The patent replaces direct mechanical attachment of sensors to the load with a non-contact or minimally intrusive measurement approach. By using sensors that measure physical quantities in the environment around the load and processing this data computationally, the system avoids the mechanical interference that would result from rigid sensor attachment, thereby preserving the load's authentic dynamic behavior.
2Measurement precision
If sensors are positioned to measure stresses directly on the load, then measurement accuracy improves, but the sensors become vulnerable to damage from impacts and collisions during transport
Solution Approach 1:
The patent positions sensors and the processing unit in locations that are inherently more protected from impacts and collisions during transport. Rather than placing sensors directly on vulnerable surfaces of the load, the system uses strategic positioning and environmental sensing that cushions the measurement components from direct mechanical damage while maintaining measurement capability.
Solution Approach 2:
The processing unit serves as an intermediary that receives data from multiple sensors and processes this information to derive accurate stress measurements. This architecture allows the use of more robust sensor placements that are less vulnerable to damage, while the computational processing maintains measurement accuracy through data fusion and analysis.
3Loss of substance
If film stretching is increased to reduce film thickness and consumption, then packaging costs decrease, but the film may become too inextensible to effectively contain and fasten the load
Solution Approach 1:
The patent uses measured physical quantities (acceleration, temperature, humidity, pressure) to dynamically adjust wrapping parameters such as film stretch ratio, wrapping force, and number of wrappings. By changing these parameters based on actual transport conditions and load characteristics, the system optimizes film usage while maintaining adequate containment capability throughout the transport journey.
Solution Approach 2:
The system implements feedback by continuously monitoring physical quantities during transport and using this information to adjust wrapping parameters. The processing unit analyzes sensor data and modifies wrapping specifications to achieve optimal balance between film consumption and load containment, ensuring that the film maintains sufficient extensibility and strength under varying transport conditions.
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
Enables precise and accurate measurement of kinematic and environmental physical quantities during transport, improving the stability and containment of palletized loads while reducing film consumption and manufacturing costs by optimizing wrapping configurations based on real-time data.
Implementation Method 1
A measuring system (1) comprising a supporting frame (2), in particular a pallet, for a load of products (100) to be wrapped with a film (50), in particular of the cold-stretchable type, a first detecting module (3) housed inside the supporting frame or pallet (2) and provided with first sensor means (13) to detect and measure with a first data acquisition time (t1) first physical quantities (a, co) of the kinematic type, in particular linear acceleration a, angular speed co
Implementation Method 2
a second detecting module (4) housed inside the supporting frame or pallet (2) and provided with second sensor means (14) to detect and measure with a second data acquisition time (t2), which is higher than the first data acquisition time (t1), second physical quantities (t, p, u) of the environment type, in particular temperature t, pressure p, humidity u
Implementation Method 3
The plastic film is generally stretched or elongated, elastically and/or plastically, before being wrapped around the load. Typically, the plastic film is elastically stretched of a pre-set quantity or percentage in order to be used at its best and to achieve physical-mechanical characteristics such as to make it more suitable to stand the forces acting on the load when moved and transported. More precisely, when the stretching force applied to the film for elongating the latter ends, the elastic springback of the film thereof causes a tightening force on the load
Implementation Method 4
the film material when duly stretched may pass from an elastic behaviour, wherein the film tends to return to its original size once the stress is over, to a plastic behaviour, wherein the film undergoes a permanent deformation and does not return to its original size once the stress ceases. In this last case, the plastic material film behaves as a flexible and inextensible element, as a rope or belt, and may be used for example, to wrap groups of unstable products that must be kept tightly fastened together
Data Source
AI summary
A measuring system associable with a group of products wrappable with a plastic film to form a palletized load. The system includes a supporting frame provided with a supporting plane for the group, first and second detecting modules housed inside the supporting frame and provided with first and second sensor units to detect and measure first and second physical quantities acting on the palletized load when it is moved and/or transported, a processing module having first and second computing units and first and second memory units positioned on the supporting plane, inserted among the products and having dimensions and weight comparable to that of one of the products. The first and second computing units, first and second memory units and first and second detecting modules form first and second measurement chains of the first and second physical quantities.