Robot Carrier Transfer With Sensor-Based Package Abnormality Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing transport systems, such as those described in Japanese Unexamined Patent Application Publication No. 2022-144293, fail to achieve efficient package transfer and risk excessive load on robots due to inefficiencies in package handling and lack of abnormality detection during transfer.
Innovation Solution
A transport system comprising a carrier, a transport robot, a sensor unit, and a detection unit that uses optical sensors and drive sensors to detect package presence and abnormalities, allowing the robot to decelerate or stop when anomalies are detected, and notify a server of any issues, thereby ensuring safe and efficient package transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an item grasping device is used for package transfer, then package handling capability is improved, but transport efficiency deteriorates and excessive load risk increases
Solution Approach 1:
The patent replaces the mechanical item grasping device with a passive carrier-based transfer system. The carrier is simply placed on the transport robot, and package transfer is achieved through the robot's movement and positioning rather than active grasping mechanisms. This substitution eliminates the complexity of grasping operations while maintaining transfer functionality, thereby improving transport efficiency and reducing load risks.
Solution Approach 2:
The patent extracts the active grasping function from the transport system and replaces it with a passive carrier system. The carrier serves as a simple container that is loaded onto the robot, and package transfer is achieved through the robot's movement to designated locations rather than through complex grasping and placing operations. This extraction of the grasping function resolves the contradiction between handling capability and transport efficiency.
2Productivity
If passive carrier transfer is used, then transport efficiency is improved, but abnormality detection capability deteriorates
Solution Approach 1:
The patent introduces sensors as intermediary devices between the carrier and the control system. These sensors detect the presence and status of packages on the carrier, providing abnormality detection capability without interfering with the simple carrier-based transfer mechanism. The sensors act as mediators that enable monitoring and detection while maintaining the efficiency of the passive transfer system.
Solution Approach 2:
The patent implements a feedback mechanism where sensors continuously monitor the carrier and package status, and this information is fed back to the control system. When abnormalities such as missing packages or improper loading are detected, the system receives feedback and can take appropriate actions. This feedback loop maintains reliability while preserving the transport efficiency of the passive carrier system.
3Reliability
If sensor-based detection is implemented, then abnormality detection is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical monitoring systems with simple sensor-based detection. Instead of using mechanical switches, physical contact sensors, or complex mechanical interlocks to detect package presence and status, the system uses optical or other non-contact sensors that provide abnormality detection with minimal added complexity. This substitution maintains reliability while avoiding significant increases in device complexity.
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 system enables efficient and safe package transfer by detecting abnormalities in real-time, preventing excessive load on the robot and ensuring accurate positioning and handling of packages, thus enhancing transport efficiency and reliability.
Implementation Method 1
The sensor unit is provided to detect presence or absence of the package on the shelf or the carrier... the sensor unit may be an optical sensor configured to detect the marker
Implementation Method 2
a drive sensor configured to detect drive information regarding drive of the wheels, and the detection unit may be configured to detect the abnormality based on the drive information... the detection unit may be configured to detect the abnormality when the drive torque of the wheels is equal to or greater than a threshold value
Data Source
AI summary
A transport system includes a carrier provided for placing a package to be transferred on a shelf or for transferring the package from the shelf, a transport robot on which the carrier is mounted and configured to move to transfer the package between the shelf and the carrier, a sensor unit provided to detect the presence or absence of the package on the shelf or the carrier, and a detection unit configured to detect an abnormality in transfer of the package according to a detection result of the sensor unit.