Four-Way Shuttle Distance Sensing for Pallet Collision Avoidance

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Solution Overview

Problem

Collisions between four-way shuttles and pallets in complex warehouse environments cannot be effectively avoided by software scheduling alone, leading to damage and risk of vehicle body and goods falling off shelves.

Innovation Solution

An obstacle avoidance and detection device for four-way shuttles equipped with directional distance sensors and a detection circuit, which use laser ranging sensors to detect distances and control speed or stop the shuttle based on set values to avoid collisions and ensure precise inventory management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If software scheduling system is used to manage four-way shuttles, then operational coordination is achieved, but collision avoidance between vehicles cannot be ensured in complex environments

Engineering Contradiction:

Improveoperational coordinationVSAvoidcollision avoidance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent introduces distance sensors as intermediary devices that detect obstacles and transmit information to the control system. These sensors act as mediators between the shuttles and the control system, providing real-time spatial information that enables automatic collision avoidance without relying solely on software scheduling

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The shuttles are equipped with their own distance sensors and control systems that independently detect obstacles and adjust movement. Each shuttle performs self-service collision avoidance by autonomously sensing its environment and making real-time adjustments to its operation

Inventive Principle:

Principle #25Self-service

2Device complexity

If inventory management system operates without real-time detection, then system simplicity is maintained, but correctness of pallet at storage positions cannot be ensured

Engineering Contradiction:

Improvesystem simplicityVSAvoidpallet position detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces manual or periodic inventory checking with automatic optical/electronic distance sensing. The distance sensors use laser or optical beams to detect pallet positions and heights, substituting mechanical inspection methods with non-contact measurement technology

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The distance sensors serve multiple functions: they detect obstacles for collision avoidance, measure pallet heights for inventory verification, and identify storage position occupancy. This multi-functionality maintains system simplicity while achieving precise measurement

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If four-way shuttles operate at high speed in complex warehouse environments, then productivity is improved, but risk of collision and goods falling from shelves increases

Engineering Contradiction:

Improveoperating speedVSAvoidcollision risk and goods falling risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The distance sensors detect obstacles and pallets at a distance before the shuttle reaches them. The control system receives advance warning and prepares to adjust speed or stop, performing preliminary action to prevent collision before it occurs

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system establishes safety buffers by detecting obstacles at predetermined distances and initiating speed reduction before the shuttle reaches dangerous proximity. This creates a temporal and spatial cushion that prevents collisions even at high operating speeds

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Prevents collisions between shuttles and pallets, identifies inventory errors, and provides real-time feedback for precise inventory management, reducing damage and loss.

Implementation Method 1

use laser ranging sensors to detect distances

Methodology Applied

Scientific EffectLaser ranging: LIDAR

Data Source

PatentUS20260099152A1Obstacle avoidance and detection device for vehicle body of four-way shuttle and pallet, and working method thereof

Publication Date: 2026.04.09 SHANGHAI ZS ROBOTICS CO LTD

AI summary

An obstacle avoidance and detection device for a vehicle body of a four-way shuttle and a pallet, and a working method thereof are provided. The device includes a four-way shuttle, pallets with goods, and Y direction tracks and an X direction track that are interlaced horizontally and longitudinally. The four-way shuttle can operate in track directions of the Y direction tracks and the X direction track. Shelf supports are arranged on two sides of the Y direction tracks. A vehicle body of the four-way shuttle is provided with distance sensors on front and rear sides in both an X direction and a Y direction. A jacking structure of the four-way shuttle is provided with distance detection sensors on front and rear sides in the Y direction. Collisions between the four-way shuttle and an obstacle or the pallets are avoided.