Sensor-Based Transporting Device Positioning for Dense Grid Warehouses
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Solution Overview
Problem
Existing load handling systems in warehousing face challenges with accurate positioning of load handling devices, leading to potential collisions and inefficiencies, particularly when target bins are not at the top of stacks, requiring slower operations and larger device spacings to minimize errors.
Innovation Solution
The implementation of a control unit that receives information from sensors, such as barcode scanners or cameras, to accurately calculate the position of load handling devices within a grid-like structure, allowing for more precise navigation and reduced spacing between devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If load handling devices operate at higher speeds to improve productivity, then throughput increases, but positioning accuracy deteriorates leading to potential collisions and operational errors
Solution Approach 1:
The system continuously receives position information from sensors (barcode scanners, cameras) mounted on the load handling device and feeds this data back to the control unit. The control unit calculates the device's position based on sensor feedback, enabling real-time position correction and maintaining accuracy even at higher operating speeds.
Solution Approach 2:
The patent replaces traditional mechanical positioning systems with optical sensing systems (barcode scanners, cameras). Instead of relying solely on mechanical encoders and physical track references, the system uses optical sensors to detect position markers and calculate device location, allowing for more precise and faster positioning.
2Reliability
If larger spacing is maintained between load handling devices to minimize collision risks, then safety improves, but device density and space utilization deteriorate
Solution Approach 1:
Real-time position feedback from sensors allows the control system to maintain precise knowledge of each device's location. This enables devices to operate closer together while maintaining safety, as the system can detect and respond to position changes immediately, reducing the need for large safety buffers.
Solution Approach 2:
Optical sensing and calculation systems provide more precise position detection than traditional mechanical methods, enabling tighter device spacing. The sensor-based positioning system can detect positions with higher resolution, allowing devices to navigate closer together without increasing collision risk.
3Measurement precision
If slower operation speeds are used to maintain positioning accuracy, then positioning precision improves, but operational efficiency and throughput deteriorate
Solution Approach 1:
The system replaces mechanical positioning with optical sensing (barcode scanners, cameras) that can accurately detect position markers at higher speeds. Optical sensors have faster response times and higher detection speeds compared to mechanical encoders, enabling accurate positioning without sacrificing operational efficiency.
Solution Approach 2:
The patent changes the measurement parameters by using optical detection instead of mechanical measurement. Optical sensors can capture position information in microseconds, whereas mechanical systems require physical contact and slower measurement cycles. This parameter change enables high-speed accurate positioning.
Data Source
AI summary
A control unit is provided to improve positioning of transporting devices to thereby allow transporting devices to be driven at faster speeds and/or accelerations with minimal positional errors allowing for a reduction in the spacing between transporting devices. A control unit is arranged to control movement of at least one transporting device for containers stored in a facility having a plurality of pathways arranged in cells so as to form a grid-like structure above the stacks which extends in a first direction and in a second direction. The control unit includes a receiving unit arranged to receive information from a first sensor mounted on the at least one transporting device, and a calculating unit arranged to calculate a position of the at least one transporting device based on the received information.