Rack Feeder Image Inspection for Pallet Misalignment
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Solution Overview
Problem
High-bay warehouse operations face challenges with pallet misalignment and errors during the outsourcing process, leading to potential shifts, tilting, or crashing of pallets, which can result in longer downtime and reduced efficiency.
Innovation Solution
A shelf control unit equipped with an image recording device and an evaluation device that captures and evaluates images of the pallets to recognize errors such as bending, loose nails, or misalignment, allowing for immediate intervention and automated correction to prevent accidents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated storage and retrieval operations are implemented, then productivity is improved, but reliability deteriorates due to pallet misalignment and potential accidents
Solution Approach 1:
The system performs preliminary inspection of pallets using image capture devices before storage operations. The evaluation device assesses pallet conditions (alignment, integrity, positioning) in advance, allowing operators to correct issues before automated handling begins, thus preventing accidents while maintaining automation
Solution Approach 2:
The system implements continuous feedback through image capture devices that monitor pallet positions and conditions during storage and retrieval operations. The evaluation device provides real-time information about pallet alignment and potential issues, enabling automatic adjustments or operator intervention to maintain reliability while preserving productivity
2Reliability
If manual inspection of pallets is performed, then reliability is improved, but productivity deteriorates due to operational interruptions
Solution Approach 1:
The system replaces manual mechanical inspection with automated image capture devices and evaluation devices that use optical and computational methods to detect pallet faults. This substitution maintains high reliability in fault detection while eliminating operational interruptions, as the automated system operates continuously without stopping the storage and retrieval process
3Productivity
If automated correction of pallet errors is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The system implements self-service correction where the storage and retrieval machine automatically adjusts its operations based on evaluation results. The control device autonomously modifies retrieval sequences, adjusts fork positioning, or redirects pallets requiring correction without human intervention, improving productivity while the modular architecture manages the inherent complexity
Data Source
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AI summary
The invention relates to a storage and retrieval machine (100) for a high-bay warehouse. The storage and retrieval machine (100) comprises a travel and lifting device (102) which moves the storage and retrieval machine (100) at least in a longitudinal direction (L) and in a vertical direction (H), and a load handling device (112) with a telescopic fork assembly (114) which is displaceable relative to the travel and lifting device (102) at least in a transverse direction (Q). According to the invention, an image acquisition device (116) is also provided, as well as an evaluation device (118) which evaluates at least one image acquired by the image acquisition device (116) according to at least one predetermined criterion and outputs a corresponding evaluation result.