Pallet Rack Vibration Detection for Load Stability
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Solution Overview
Problem
Conventional inventory management systems are prone to errors and provide limited information regarding pallet weight, stability, and position, requiring significant new infrastructure and being non-retrofitable to existing systems.
Innovation Solution
A controller-implemented method and system using exciters and harvesters to generate and detect mechanical vibrations in pallet racks, allowing for accurate detection of load characteristics and stability assessment without extensive infrastructure changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If optics-based systems with laser depth sensors and three-dimensional computerized models are used to track pallets, then automated storage and retrieval can be achieved, but the systems are susceptible to errors and provide limited information regarding pallet weight, stability, and position
Solution Approach 1:
The patent replaces optics-based detection systems with a mechanical vibration-based system. Exciters generate mechanical vibrations in the pallet rack, and harvesters detect these vibrations to determine pallet characteristics. This mechanical approach provides more reliable measurements of weight, stability, and position compared to optical systems, directly resolving the contradiction between automation and measurement accuracy.
2Extent of automation
If optics-based systems with laser depth sensors and three-dimensional computerized models are used to track pallets, then automated storage and retrieval can be achieved, but a substantial amount of new infrastructure is required and the systems are not readily retrofittable to existing pallet racks
Solution Approach 1:
The pallet rack itself serves as the sensing medium. The rack's natural vibrations are used to detect pallet characteristics, eliminating the need for separate complex sensing infrastructure. The exciters and harvesters attach directly to the existing rack structure, allowing the system to retrofittable to existing pallet racks while maintaining automation capabilities.
3Loss of information
If conventional inventory management systems are used, then inventory tracking can be performed, but the systems provide limited information with regards to the weight of individual pallets, cumulative weight of pallets on a given pallet rack, the relative positions of pallets on a given rack, the number of pallets per pallet or pallet rack, and the stability of pallets on a pallet rack
Solution Approach 1:
The vibration-based detection system performs multiple functions simultaneously: it measures pallet weight, position, quantity, and stability all through a single mechanical sensing mechanism. This multi-functional approach provides comprehensive inventory information without requiring separate complex systems for each measurement type, resolving the contradiction between information completeness and system complexity.
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
Provides reliable and intuitive feedback on pallet and pallet rack load characteristics and stability, enabling efficient digitalization and remote management of inventory with minimal additional infrastructure.
Implementation Method 1
engaging a plurality of exciters to generate a rack frequency in the pallet rack
Implementation Method 2
receiving the rack frequency at a plurality of corresponding harvesters
Data Source
AI summary
A controller-implemented method for managing inventory of pallets on a pallet rack is provided. The controller-implemented method may include engaging a plurality of exciters to generate a rack frequency in the pallet rack, receiving the rack frequency at a plurality of corresponding harvesters, detecting variations between the rack frequency generated by the exciters and the rack frequency received by the harvesters, and detecting one or more load characteristics of pallets on the pallet rack based on the variations.