Picker-Aware Access Station Control to Prevent Container Pinch Hazards
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Solution Overview
Problem
The combination of moving containers and human pickers and packers in automated storage and retrieval systems introduces safety concerns due to the potential for pinching or trapping of body parts between moving containers and static or moving parts of the access station.
Innovation Solution
An access station with sensors to detect picker movement and actuators to control container movement, preventing the container from moving when the picker enters a risky area, thereby reducing the risk of pinching or trapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated storage and retrieval systems use moving containers to improve space utilization and productivity, then storage efficiency and picking speed are improved, but safety risks increase due to potential pinching or trapping of body parts between moving containers and access station parts
Solution Approach 1:
The sensor detects picker movement in advance before the picker enters the dangerous zone. The system performs preliminary detection and triggers a warning signal or stops container movement before the harmful event can occur, preventing pinching or trapping incidents.
Solution Approach 2:
The system continuously monitors the area around the access station using sensors and provides real-time feedback about picker position. When the sensor detects movement indicating the picker is approaching or entering the dangerous zone, the system responds by stopping container movement or activating warnings, creating a closed-loop safety control mechanism.
2Object-affected harmful factors
If sensors and control systems are added to monitor picker movement and control container movement, then safety is improved, but device complexity increases
Solution Approach 1:
A sensor acts as an intermediary element between the picker and the container movement system. The sensor detects picker movement and transmits this information to the control system, which then controls the actuator to stop or prevent container movement. This intermediary sensing mechanism enables safety control without requiring complex direct interaction monitoring.
3Object-affected harmful factors
If the access station automatically stops container movement in response to detected picker movement, then safety is improved, but productivity may be reduced due to movement interruptions
Solution Approach 1:
The control system applies partial action by stopping container movement only when and where necessary - specifically when the sensor detects picker movement indicating entry into the dangerous zone. Normal container movement and picking operations continue uninterrupted when no safety risk is detected, minimizing productivity impact while maintaining safety.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The disclosure relates to an access station for presentation of a storage container from an automated storage and retrieval system for picking, wherein the access station comprises: a frame; an actuator arranged to move relative to the frame to control movement of a storage container relative to the frame; a sensor arranged to detect movement of a picker relative to the frame; one or more controllers arranged to control the movement of the actuator based on the movement of the picker so as to prevent the movement of the storage container relative to the frame.