Storage Rack Case Detection After Seismic Displacement
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Solution Overview
Problem
Automated storage and retrieval systems face challenges in detecting and repositioning case units that have been displaced due to seismic events or other disturbances, affecting their retrievability and storage efficiency.
Innovation Solution
The system employs a disturbance identification and restorative system that includes sensors and autonomous transport robots to map the storage structure, identify displaced case units, and reposition them, utilizing a controller to manage the storage and retrieval operations, ensuring accurate placement and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated storage and retrieval systems use traditional detection methods, then system complexity is reduced, but the ability to detect and reposition displaced case units after disturbances deteriorates
Solution Approach 1:
The system performs preliminary mapping of the storage structure and case unit positions before disturbances occur. This allows the system to have baseline data ready for comparison, enabling faster and more accurate detection of displacements without requiring complex real-time analysis during emergency situations.
Solution Approach 2:
The system implements continuous feedback loops where sensors monitor case unit positions, the controller compares actual positions with expected positions from the map, and transport robots automatically correct any displacements. This closed-loop feedback mechanism enhances detection reliability while keeping system complexity manageable through automated decision-making.
2Measurement precision
If the system implements comprehensive mapping and detection of all case units, then measurement precision improves, but the time required for detection and repositioning increases
Solution Approach 1:
The storage structure is divided into multiple zones or sections that can be mapped and monitored independently. This segmentation allows the system to process position data in manageable chunks, maintaining high measurement precision for each segment while reducing the total time required to survey the entire storage facility.
Solution Approach 2:
The system creates and stores a complete map of case unit positions in advance, organizing data by location and characteristics. When a disturbance occurs, the system only needs to compare current sensor readings against this pre-existing map, significantly reducing detection time while maintaining precise measurement capabilities.
3Productivity
If the system uses autonomous transport robots for repositioning, then operational efficiency improves, but device complexity increases
Solution Approach 1:
The transport robots are equipped with autonomous navigation and case unit handling capabilities, allowing them to independently locate displaced case units, calculate optimal repositioning destinations using the stored map, and execute repositioning operations without human intervention. This self-service capability maximizes productivity while the modular robot design keeps individual unit complexity manageable.
Solution Approach 2:
The transport robots are designed as multi-functional units that can perform multiple tasks: navigating autonomously, detecting case unit positions, transporting various types of case units, and repositioning them to correct locations. This universality improves overall system productivity by using a single platform for multiple operations, though it does increase individual robot complexity.
4Reliability
If the system continuously monitors and repositions case units, then storage system integrity is maintained, but energy consumption increases
Solution Approach 1:
Instead of continuous monitoring and repositioning, the system employs periodic sensing and disturbance-triggered activation. Sensors take snapshots of case unit positions at intervals or when disturbances are detected, and transport robots are activated only when displacements are identified. This periodic approach maintains storage integrity while dramatically reducing energy consumption compared to continuous operation.
Solution Approach 2:
The system uses feedback-based activation where sensors monitor for changes from the mapped positions and only trigger repositioning operations when actual displacements are detected. This feedback mechanism ensures storage integrity is maintained by addressing only when necessary, avoiding unnecessary energy consumption from continuous or preventive repositioning operations.
Data Source
AI summary
An automated storage and retrieval system including a storage structure with storage racks having a seating surface configured to support case units where a position of each case unit is nondeterministic for each storage location on the storage racks, each case unit has a predetermined storage position and a controller is configured to determine the predetermined storage position, a picking aisle configured to provide access to the case units within the storage structure, and a seismic disturbance restorative system including seismic disturbance motions sensors disposed on the storage racks, a seismic disturbance control module in communication with the seismic disturbance sensors and configured to identify a seismic disturbance, and an automated case mapper configured to traverse the picking aisle, the automated case mapper being in communication with and initialized by the seismic disturbance control module to identify a seated position of at least one case unit within the storage structure.