Rack Operating Device Control Using Simulation-Based Setpoint Tables
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Solution Overview
Problem
Existing methods for controlling storage and retrieval devices fail to accurately describe their dynamic behavior, leading to vibrations that cannot be adequately damped without additional devices, and require separate correction mechanisms.
Innovation Solution
A method where setpoints for travel and lifting drives are calculated numerically using a simulation model and stored in tabular form, allowing the control device to control the device with target values that accurately describe the dynamic behavior, enabling optimized movement without waiting for vibrations to subside.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flatness-based control with mathematical reference trajectories is used, then the dynamic behavior can be modeled, but the accuracy is insufficient leading to vibrations
Solution Approach 1:
The patent replaces the mathematical model-based control approach with a data-driven approach using measured actual values from sensors. Instead of relying on theoretical equations that cannot accurately predict vibrations, the system uses empirical data from accelerometers and other sensors to detect and correct deviations in real-time, substituting mechanical/mathematical modeling with direct measurement and feedback.
Solution Approach 2:
The patent implements a feedback mechanism where actual values from sensors (accelerometers, position sensors) are continuously measured and compared against target values. The control device uses this feedback to generate correction values that adjust the actuating forces, thereby reducing vibrations and improving accuracy of the dynamic behavior control.
2Object-generated harmful factors
If separate damping devices and sequence control are added to correct deviations, then vibrations can be damped, but the device complexity increases
Solution Approach 1:
The patent enables the storage and retrieval device to self-correct its dynamic behavior by using its own sensors and control system. The actual values measured by onboard sensors are directly fed into the control device, which automatically generates correction values without requiring external damping devices or complex sequence control from outside the system.
Solution Approach 2:
The patent merges the control function and damping function into a single integrated control device. Instead of having separate damping devices and separate sequence control systems, the control device performs both functions by processing sensor data and generating corrected actuating forces that simultaneously control motion and reduce vibrations.
3Measurement precision
If waiting for vibrations to subside is required, then accuracy is improved, but the productivity decreases
Solution Approach 1:
The patent applies preliminary correction actions during the motion process itself, rather than waiting for vibrations to subside naturally after movement completes. By continuously measuring actual values and applying correction values in real-time, the system proactively prevents vibrations from developing or amplifying, allowing faster movement while maintaining accuracy.
Solution Approach 2:
The real-time feedback mechanism allows the system to maintain position accuracy during high-speed operation by continuously comparing actual position and motion parameters against targets and applying corrective forces, eliminating the need to slow down or wait for vibrations to decay.
Data Source
Figure 1
AI summary
The invention relates to a method for controlling a rack operating device (1). The rack operating device comprises: a chassis (3), which bears a mast (5) and which has a traversing drive (4); a load holder (6), which can be moved along the mast (5) by means of a lifting drive (10); and a control device (11) for the traversing and lifting drives (4, 10). The traversing and lifting drives (4, 10) are controlled by means of target values, which take into account the dynamic behaviour of the rack operating device (1), in order to move the chassis (3) and the load holder (6) in accordance with the specifications determined by the particular initial position and end position and the particular load (7). In order to create advantageous control conditions, it is proposed that the target values required for the control of the traversing and lifting drives (4, 10) in accordance with the specifications are calculated numerically on the basis of a simulation model of the rack operating device (1) for all specification combinations and are stored in tabular form with assignment to the individual specification combinations and that the control device (11), in order to move the chassis (3) and the load holder (6) in accordance with a specification combination, controls the traversing and lifting drives (4, 10) by means of the target values stored in tabular form for said specification combination.