Rack Contour Checking Using Stationary Sensors
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Solution Overview
Problem
Existing contour checking devices for pallets in rack systems are expensive, space-intensive, and difficult to retrofit into existing systems, posing a risk of damage and downtime due to potential collisions with system components or other pallets if contours are not maintained.
Innovation Solution
A contour checking arrangement that includes a pallet transfer station with a sensor device, such as a light barrier or camera, for stationary pallets, which can be easily retrofitted into existing rack systems, eliminating the need for a conveyor belt and providing a cost-effective and space-efficient solution for checking pallet contours and objects against pre-defined dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conveyor belt system with cameras is used for contour checking, then measurement precision is improved, but device complexity and space requirements increase significantly
Solution Approach 1:
The patent extracts the essential function of contour checking from the complex conveyor belt system and implements it using a simple sensor device positioned at the rack location. This removes the unnecessary conveyor belt infrastructure while retaining the core measurement capability, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent replaces the mechanical conveyor belt system with a stationary sensor-based detection system. Instead of mechanically transporting pallets through a camera frame, the solution uses optical or other sensor fields to detect contour compliance at the storage location, eliminating mechanical complexity while preserving measurement accuracy.
2Measurement precision
If a conveyor belt system with cameras is used for contour checking, then measurement precision is improved, but the space requirement and installation costs increase
Solution Approach 1:
The patent extracts the contour checking function from the space-intensive conveyor system and relocates it to the rack position. This allows the measurement function to be performed in-place at the storage location, eliminating the need for additional conveyor space and reducing the overall footprint of the checking system.
3Reliability
If a conveyor belt system with cameras is used for contour checking, then reliability of contour detection is improved, but ease of retrofitting into existing systems deteriorates
Solution Approach 1:
The patent extracts the contour checking function from the fixed conveyor system and implements it as a standalone sensor device that can be independently positioned at the rack location. This modular approach allows the system to be retrofitted into existing rack systems without requiring conveyor belt infrastructure, thereby maintaining detection reliability while improving adaptability.
4Reliability
If contour checking is performed close to the storage location, then reliability of ensuring contour compliance is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical conveyor systems with simple stationary sensor devices positioned at the rack location. This substitution maintains the advantage of performing checks close to the storage location while dramatically reducing system complexity by eliminating the need for mechanical transport infrastructure.
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
The solution allows for reliable contour checks close to the storage location, preventing collisions and damage, while being cost-effective and easily integratable into existing systems, maximizing throughput and minimizing downtime.
Implementation Method 1
the sensor device can comprise at least one light barrier and/or at least one camera, for example a 3D camera
Implementation Method 2
a three-dimensional image of the pallet and the objects carried thereby can be produced by means of modern camera systems, such as stereo cameras for example
Data Source
AI summary
The invention relates to an arrangement for checking contours of pallets (18) to be put into storage in a rack system, said arrangement comprising: a pallet transfer station (12) which is designed to receive pallets (18) to be put into storage in the rack system; at least one sensor device (16a-16d) which is designed to detect whether a pallet (18) standing on the pallet transfer station (12) and objects supported by the pallet (18) are completely within a predefined contour; and an output unit (24) which is operationally coupled to the sensor unit (16a-16d) and is designed to output the detection result. The invention also relates to a rack system comprising at least one rack row, at least one stacker crane and at least one arrangement for checking contours, the pallet transfer station of which is designed such that pallets can be placed thereon from outside the rack system, which pallets can then be picked up by the stacker crane so as to be put into storage.