Movable Rack Alignment Control Using Floor-Embedded Magnets

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Solution Overview

Problem

Conventional movable rack systems in narrow spaces, like warehouses, face difficulties in maintaining widthwise shift control without using a sheet rail member, which is cumbersome to construct and prone to damage.

Innovation Solution

The system employs magnets at stop positions and magnetic sensors to detect widthwise shifts, allowing the control unit to adjust motor speeds and travel routes to correct deviations without the need for a sheet rail member, ensuring accurate alignment and preventing collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a sheet rail member is used for widthwise shift control, then the movable rack can maintain accurate alignment, but the construction becomes cumbersome and the rail member is prone to damage

Engineering Contradiction:

Improvealignment accuracyVSAvoidconstruction complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts the detection function from the sheet rail member and relocates it to magnets embedded in the floor. This removes the need for a visible, exposed rail member while maintaining the alignment detection capability. The magnets are embedded below the floor surface, eliminating the structural complexity and vulnerability of exposed rail members.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical sheet rail member with a magnetic detection system. Instead of using a physical rail that requires robust construction, the system uses magnets and magnetic sensors to detect widthwise shifts, substituting a mechanical structure with a field-based detection method that is less complex and more durable.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a sheet rail member is exposed on the corridor surface, then widthwise shift can be detected, but it is vulnerable to damage from treading by workers or service vehicles

Engineering Contradiction:

Improvedetection reliabilityVSAvoiddamage resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent embeds the magnets within the floor structure, nesting the detection component inside the floor rather than exposing it on the surface. This protective embedding shields the detection elements from damage by workers or vehicles while maintaining detection functionality through the floor surface.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The floor surface acts as an intermediary layer between the magnetic detection elements and the external environment. The magnets are positioned below the floor, using the floor itself as a protective medium that transmits magnetic fields while preventing physical damage to the detection components.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the movable rack travels at high speed, then productivity is improved, but the widthwise shift control becomes more difficult without a sheet rail member

Engineering Contradiction:

Improvetravel speedVSAvoidshift detection accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent implements a feedback control system where magnetic sensors continuously detect the position of the movable rack relative to embedded magnets, and the control unit adjusts the driving motors in real-time to correct widthwise shifts. This feedback mechanism maintains detection accuracy even at higher travel speeds by providing continuous correction.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses the movable rack's own movement to trigger detection and correction. As the rack travels, its position relative to the embedded magnets automatically activates the detection and correction mechanisms, allowing the system to self-regulate alignment without requiring external guidance infrastructure.

Inventive Principle:

Principle #25Self-service

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 effective widthwise shift control without the need for a sheet rail member, simplifying construction and reducing the risk of damage, while maintaining accurate alignment and preventing collisions between racks.

Implementation Method 1

widthwise shift detection means being provided on the respective movable racks for detecting a widthwise shift of the movable rack from the travel path in the left and right direction perpendicular to the extending direction of the travel path by detecting the members to be detected

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Data Source

PatentUS8607911B2Moving shelf equipment

Publication Date: 2013.12.17 DAIFUKU CO LTD

AI summary

A movable rack system able to carry out a widthwise shift control of a movable rack without using a sheet rail member to be detected. The system is so configured, that magnets are placed at stop positions of the movable rack on the floor surface as members to be detected, while the movable rack is equipped with magnetic sensors to detect the magnets. When the movable rack stops traveling, the magnetic sensors detect the magnets and compares the detected magnetic intensity to the magnetic intensity detected at the previous stop. If the change exceeds a pre-determined value, namely the widthwise shift exceeding a pre-determined value is detected, a travel route of the movable rack to eliminate the widthwise shift is determined. In the next travel of the movable rack the rotation speeds of the respective driving motors are controlled so that the movable rack follows the travel route.