Shuttle Vehicle Laser Scanner for Shelf Collision Prevention
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Solution Overview
Problem
Existing automated transport systems for rack shuttle vehicles lack reliable mechanisms to prevent collisions with shelf ends, leading to potential crashes and damage.
Innovation Solution
A system equipped with a laser scanner that monitors a protective field with multiple detection areas, including a first protection area and additional detection areas that recognize information signs at the ends of storage rails, allowing for precise detection and prevention of vehicle movement beyond shelf limits, and includes a safety function to handle uncertainties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactless proximity sensors are used to detect shelf ends, then the shuttle vehicle can stop before crashing, but the system requires complex sensor arrangements and may not be universally applicable to all rack systems
Solution Approach 1:
The patent replaces complex mechanical sensor arrangements with a laser scanner that uses optical fields to detect information signs. The laser scanner projects laser beams that reflect off the information signs attached to shelf ends, providing reliable crash prevention through optical detection rather than mechanical contact sensors.
Solution Approach 2:
The system achieves universal applicability across different rack systems by using simple information signs that can be attached to any shelf end, rather than requiring rack-specific sensor integration. The laser scanner can detect these signs on various rack configurations, making the system adaptable to different storage systems.
2Strength
If mechanical stop plates are installed at shelf ends, then the shuttle vehicle is protected from damage, but the system cannot prevent the vehicle from approaching the shelf end, only react after contact
Solution Approach 1:
The patent implements preliminary action by detecting information signs with the laser scanner before the shuttle vehicle reaches the shelf end. The system triggers a stop command in advance, preventing the vehicle from approaching the dangerous zone rather than merely reacting after contact occurs.
Solution Approach 2:
The patent replaces the passive mechanical stop plate approach with an active optical detection system. Instead of relying solely on mechanical contact to trigger protection, the laser scanner detects information signs and initiates preventive stopping, transforming the system from reactive to proactive protection.
3Reliability
If multiple sensor elements are used to monitor relative positions, then detection reliability improves, but the device complexity and cost increase
Solution Approach 1:
The patent replaces multiple mechanical sensor elements with a single laser scanner that uses optical fields for detection. The laser scanner can detect multiple information signs simultaneously using its scanning capability, achieving reliable position detection without requiring multiple separate sensors.
Solution Approach 2:
The laser scanner serves multiple functions: it detects information signs at different positions, determines distance to shelf ends, and provides redundancy through multiple detection zones. This single multi-functional device replaces what would otherwise require multiple specialized sensors.
4Speed
If light sensors are used to measure distance and trigger speed reduction, then the vehicle can slow down before reaching the shelf end, but the system lacks redundant detection zones for enhanced safety
Solution Approach 1:
The patent segments the detection space into multiple distinct zones: a first detection zone for early information sign detection, a second detection zone for confirmation, and a third detection zone for redundant verification. This segmentation allows progressive speed reduction and provides multiple layers of safety redundancy.
Solution Approach 2:
The system implements feedback through multiple detection zones that continuously monitor the vehicle's approach to shelf ends. Each zone provides feedback signals that trigger appropriate speed adjustments, with redundant zones ensuring that failure of one detection mechanism does not compromise safety.
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
Ensures reliable and safe operation by preventing collisions with shelf ends, allowing for easy retrofitting and adaptable use across various shelving systems, reducing the risk of unintentional stops and enhancing security by redundant detection and speed control.
Implementation Method 1
The at least one rack shuttle vehicle is equipped with a laser scanner that monitors a protective field located along a direction of travel of the vehicle
Data Source
Figure 1a~1b
Figure 2
Figure 2a~2b
AI summary
System comprising at least one rack shuttle vehicle and at least one storage rack equipped with a pair of storage rails, in which the rack shuttle vehicle can pick up, move and set down loads, wherein the at least one rack shuttle vehicle has a laser scanner that monitors a protective field located along one direction of travel of the vehicle, which has at least a first protection area and at least a second detection area, wherein the first protection area has a width transverse to the longitudinal direction of the vehicle that is less than or equal to the vehicle width, wherein indicator signs are attached to the storage racks at the end of the storage rails, which are detected when the rack shuttle vehicle approaches the second detection area and are transmitted to the vehicle control system as detected indicator signs.