Rotating Laser Sensor for Automated Storage Crane Collision Avoidance
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Solution Overview
Problem
Automated Storage and Retrieval Machines (SRM) in warehouses often collide with improperly positioned pallets or unit loads due to mechanical failures or human intervention, causing damage to the SRM.
Innovation Solution
A laser-based crash prevention system that uses sensor apparatuses to detect obstructions by generating a detection pattern of laser beams, which, when an obstruction is detected, triggers a fault condition to terminate the SRM's movement, preventing collisions. The system includes a processor and user interface for monitoring and displaying fault data, and can be mounted on a crane mast to cover both sides of the SRM's path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the SRM operates at high speed to improve productivity, then productivity increases, but the risk of collision with obstructions increases
Solution Approach 1:
The laser sensor apparatus detects obstructions in advance by projecting laser beams ahead of the SRM's path, allowing the control system to terminate movement before collision occurs. This preliminary detection action enables high-speed operation while maintaining safety through proactive obstruction identification.
2Device complexity
If the SRM operates without a crash prevention system to reduce device complexity, then device complexity decreases, but harmful factors from obstructions increase
Solution Approach 1:
The patent replaces complex mechanical collision avoidance systems with an optical detection system using laser beams. The sensor apparatus projects laser beams and detects obstructions optically, triggering electronic control to terminate movement, thereby reducing mechanical complexity while effectively preventing collision damage.
3Device complexity
If a single sensor apparatus is used to reduce device complexity, then device complexity decreases, but measurement precision for detecting obstructions from all directions decreases
Solution Approach 1:
The sensor apparatus is mounted on the movable SRM platform, making it a dynamic detection system that moves with the vehicle. This dynamic positioning allows a single sensor apparatus to cover the forward path effectively, as the detection zone moves with the SRM, maintaining measurement precision without requiring multiple fixed sensors.
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
Effectively prevents collisions between the SRM and obstructions by detecting them in time to stop the machine, reducing damage and ensuring safe operation, with a detection range of up to 47 feet and the ability to handle obstructions from either side of the path.
Implementation Method 1
a sensor apparatus for generating at least one laser beam that forms a detection pattern for detecting an obstruction in the path of the vehicle
Data Source
AI summary
A crash prevention system mounted to the crane mast for a storage and retrieval machine having a rotating sensor apparatus for forming a circular detection pattern that detects an obstruction along the entire front or back of the crane mast is disclosed. A processor in operative communication with the rotating sensor apparatus generates a fault condition that terminates the movement of the storage and retrieval machine and prevents contact with the obstruction.