Robotic Pallet Cart Sensor Alignment for Vertical Gap Precision

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Solution Overview

Problem

In high-density multi-level warehouse storage systems, the staggered alignment of gaps between pallets leads to logistical challenges, such as delayed smoke detection in case of a fire and inefficient water distribution from sprinkler systems.

Innovation Solution

A system and method using robotic pallet transportation carts equipped with sensors and indicators on the storage rack rails to ensure uniform spacing and vertical alignment of pallet gaps, regardless of minor variations in pallet dimensions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If robotic pallet transportation carts are used to load and unload pallets from high-density storage racks, then productivity is improved, but manufacturing precision deteriorates due to accumulation of dimensional variations in pallet spacing

Engineering Contradiction:

Improvepallet loading and unloading efficiencyVSAvoidpallet gap alignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces manual measurement and adjustment methods with an automated optical measurement system. Sensors mounted on the robotic cart detect the position of pallets and calculate spacing dimensions, eliminating the need for manual intervention in measurement operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system continuously measures actual pallet spacing using sensors and provides feedback to the control system. Based on this feedback, the robotic cart automatically adjusts its positioning to compensate for dimensional variations, ensuring consistent gap alignment across all pallets.

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If pallets are loaded with minor dimensional variations, then adaptability is improved, but manufacturing precision deteriorates as differences accumulate through multiple pallets

Engineering Contradiction:

Improveability to handle different pallet dimensionsVSAvoidcumulative pallet spacing consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts positioning parameters based on measured pallet dimensions. The control system calculates the actual spacing between pallets and modifies the cart's movement parameters to maintain consistent gaps, accommodating variations in pallet dimensions while ensuring uniform spacing.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Before loading pallets into the storage rack, the system performs preliminary measurements of each pallet's dimensions and position. This preliminary action allows the control system to pre-calculate the necessary adjustments to maintain consistent spacing throughout the loading sequence.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If pallet gaps are not vertically aligned across multiple levels, then ease of operation is improved, but object-affected harmful factors worsen due to delayed smoke detection and inefficient sprinkler distribution

Engineering Contradiction:

Improveflexibility in pallet arrangementVSAvoidfire safety performance

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces traditional mechanical alignment methods with an automated sensor-based measurement and control system. Optical sensors detect pallet positions and the control system calculates the necessary adjustments to achieve vertical alignment of gaps across multiple storage levels.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses visual indicators or marked reference points on the storage rack to guide the robotic cart in achieving proper alignment. These visual cues help the sensor system accurately determine when pallets are positioned correctly relative to each other across levels.

Inventive Principle:

Principle #32Color changes

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 enables precise vertical alignment of pallet gaps across multiple levels, enhancing fire safety by facilitating quicker smoke detection and improving water distribution from sprinkler systems.

Implementation Method 1

The cart has one or more sensors (optical, magnetic and otherwise) on a side of the cart to detect the indicators on the rail side

Methodology Applied

Scientific EffectOptical detection: Photoelectric Effect

Data Source

PatentUS20250051096A1Pallet spacing system and method

Publication Date: 2025.02.13 FRAZIER INDUSTRIAL COMPANY

AI summary

A system and method for operating robotic pallet transportation carts and providing uniform spacing between pallets of goods, to improve the vertical alignment of the gaps between the pallets of a multilevel commercial warehouse rack. Indicators are positioned along a storage lane, such as on side walls of cart support rail structures, on the left and/or right sides with respect to the pallet transportation cart. The cart has one or more sensors (optical, magnetic and otherwise), such as on a side of the cart to detect the indicators on the side of the lane. The cart is programmed to count the indicators and lower the pallet of goods after sensing a selected indicator number. By spacing the indicators an appropriate distance apart, the pallets can be arranged to have vertically aligned gaps, even if there are minor variations in the length of pallets of goods.