Four-Way Shuttle Sensor Layout for Pallet Collision Avoidance

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Solution Overview

Problem

Four-way shuttles in warehouse logistics face challenges in avoiding collisions due to complex operating environments, leading to potential damage and goods falling off shelves, which existing software scheduling systems cannot adequately address.

Innovation Solution

An obstacle avoidance and detection device for four-way shuttles equipped with directional distance sensors and a detection circuit, allowing real-time detection of obstacles and pallet positions to control speed and stop the shuttle to prevent collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If only a software scheduling system is used for collision avoidance, then the system complexity is low, but the collision avoidance reliability is insufficient in complex operating environments

Engineering Contradiction:

Improvecollision avoidance reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the purely software-based scheduling system with a hardware sensing system (distance sensors) that directly detects obstacles and triggers braking. This substitution of mechanical/physical detection for software logic significantly improves collision avoidance reliability in complex environments where software scheduling may fail.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces distance sensors as an intermediary between the shuttle and obstacles. These sensors act as a mediator that provides real-time spatial information, enabling the control system to make informed decisions about collision avoidance without relying solely on software scheduling algorithms.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If no obstacle detection device is installed, then the device complexity is low, but goods collisions occur causing damage to vehicle body and goods

Engineering Contradiction:

Improvevehicle body integrityVSAvoiddetection device complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent implements preliminary action by detecting obstacles before collision occurs. The distance sensors continuously monitor the environment and trigger braking when obstacles are detected within safe distances, preventing vehicle body damage and goods collision before they happen.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies beforehand cushioning by using distance sensors to detect potential collision risks in advance. The system prepares for collision avoidance by triggering braking actions before actual contact occurs, cushioning against potential damage to the vehicle body and goods.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If the four-way shuttle operates at high speed for efficiency, then the productivity is high, but the risk of collision and goods falling from shelf increases

Engineering Contradiction:

Improveoperating efficiencyVSAvoidoperational safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements feedback control by using distance sensors to continuously monitor the environment and provide real-time information to the control system. When obstacles are detected within safe distances, the system provides feedback to reduce speed or stop, maintaining high productivity while ensuring operational safety through dynamic speed adjustment.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent applies dynamics by making the shuttle's speed adjustable based on real-time sensor feedback. The system dynamically transitions between high-speed operation for efficiency and low-speed or stopped operation for safety, optimizing both productivity and reliability according to environmental conditions.

Inventive Principle:

Principle #15Dynamics

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

an obstacle avoidance sensor module comprising a Y+ distance detection sensor (14), a Y- distance detection sensor (13), a Y+ directional distance sensor (16), a Y- directional distance sensor (15), an X+ directional distance sensor (17) and an X- directional distance sensor (18)

Methodology Applied

Scientific EffectTime of Flight: Time of Flight

Data Source

PatentEP4714867A1Body and pallet obstacle avoidance detection device of four-way shuttle and operating method therefor

Publication Date: 2026.03.25 SHANGHAI ZS ROBOTICS CO LTD

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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.