Movable ToF Fill-Level Measurement Across Storage Rows
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Solution Overview
Problem
Current inventory management systems in warehouses and vending machines require multiple sensors for each storage and dispensing device to accurately track inventory levels, which is inefficient and costly, especially for large setups.
Innovation Solution
A method and system using a movable displacement sensor that can detect the distance and fill level of multiple storage and output devices with a single sensor, employing a Time of Flight (ToF) sensor with an adjustable field of view, allowing for efficient measurement of inventory levels across multiple rows with minimal hardware requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used for each storage and dispensing device to accurately track inventory levels, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
A single displacement sensor is designed to perform multiple measurement functions by moving to different positions. The sensor can measure inventory levels across multiple storage and dispensing devices sequentially, making one sensor universal for what previously required many sensors. This reduces device complexity while maintaining measurement precision through systematic positioning and measurement procedures.
Solution Approach 2:
The measurement system transitions from static multiple sensors to a dynamic single sensor that moves through different positions. The sensor is moved along a measurement path to capture data from multiple storage and dispensing devices at different locations, enabling one sensor to replace many static sensors while maintaining comprehensive monitoring capability.
2Device complexity
If a single movable sensor is used to detect multiple storage and dispensing devices, then device complexity is reduced, but measurement precision may deteriorate due to movement and positioning variations
Solution Approach 1:
The system incorporates feedback mechanisms where the sensor's position information is continuously tracked and used to correlate measurements with specific storage and dispensing devices. This feedback loop ensures that even though the sensor moves, the system maintains accurate knowledge of which device is being measured at each moment, preserving measurement precision while enabling device complexity reduction.
Solution Approach 2:
The patent replaces a mechanical system of multiple fixed sensors with a single movable sensor combined with control and positioning systems. This substitution uses automated movement and positioning control to achieve what previously required multiple stationary components, reducing overall system complexity while maintaining measurement capabilities through systematic scanning and data correlation.
3Productivity
If multiple sensors are deployed across large storage systems, then productivity of inventory monitoring is improved, but loss of substance increases due to more sensor materials and installation resources
Solution Approach 1:
A single displacement sensor is designed to perform multiple measurement functions by moving to different positions. The sensor can measure inventory levels across multiple storage and dispensing devices sequentially, making one sensor universal for what previously required many sensors. This reduces device complexity while maintaining measurement precision through systematic positioning and measurement procedures.
Solution Approach 2:
Instead of deploying multiple sensors simultaneously across the system, the invention uses a single sensor that is moved and reused across different measurement locations. The sensor is effectively 'recovered' after each measurement position and redeployed to the next location, reducing the total material consumption and installation resources required while maintaining comprehensive monitoring 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
Enables timely and accurate tracking of inventory levels with reduced sensor usage, providing up-to-date information for efficient logistics and easy retrofits, particularly suitable for vending machines and large storage systems.
Implementation Method 1
The measuring device has a number N3 of displacement sensors 31, in particular Time of Flight (ToF) sensors
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
The invention relates to a method (V) for XY measurement of the real state of object positions and geometries of a plurality of N2 storage and output devices (2) for recording objects (1), which are arranged consecutively adjacent in a first direction (X), wherein the storage and output devices (2) are arranged consecutively adjacent in a row in a second direction (Y); using a measuring device (3) movable in the second direction (Y) with a sensor (31), comprising the steps: - in a first step (S1) the measuring device (3) is arranged movable relative to the storage and output devices (2) in the second direction (Y) and adjusted;- In a second step (S2), a reference run of the measuring device (3) in the second direction (Y) is performed with a continuous measurement of the distance (D) between the storage and output units (2), and a profile (P) of the storage and output units (2) is determined from this, and a measurement position (Pmess) in the second direction (Y) is determined from the profile (P) for each storage and output unit (2); - In a third step (S3), a measurement run of the measuring device (3) in the second direction (Y) is performed with a continuous measurement of the distance (D), and for each distance (D) determined at the measurement positions (Pmess), a fill level (F) of a storage and output unit (2) is determined, which corresponds to the measurement position (Pmess). The invention also relates to a measuring system suitable for carrying out the method, comprising the measuring device (3) and a guide device (4).