Stocker Shelf Flatness Detection Using Displacement Sensors
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Solution Overview
Problem
The existing stocker systems face challenges in efficiently examining and maintaining the flatness of shelves due to their narrow, contaminated internal spaces, which can lead to product damage from inclined or deformed shelves.
Innovation Solution
A stocker system equipped with a sensor unit on the arm part that includes displacement sensors to measure relative positions between the sensor unit and the shelves, allowing for the determination of shelf flatness without physical contact, and a control unit for wireless communication to assess the flatness of each shelf.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If workers or equipment are used to examine shelves, then shelf flatness can be checked, but the clean state of the stocker interior is compromised and contamination occurs
Solution Approach 1:
The patent replaces mechanical examination methods (workers or equipment physically entering the stocker) with a sensor unit that uses optical or electromagnetic fields to measure shelf flatness. The sensor unit mounted on the rack master can detect shelf conditions without physical contact, thus avoiding contamination while maintaining measurement capability
Solution Approach 2:
The sensor unit acts as an intermediary between the examination system and the shelf. It transmits measurement data about shelf flatness without requiring direct human or equipment intervention inside the stocker, thereby preventing contamination while enabling continuous monitoring
2Measurement precision
If workers examine shelves manually, then shelf conditions can be assessed, but the narrow space of the stocker makes examination inefficient
Solution Approach 1:
The system enables self-service examination where the rack master with the integrated sensor unit automatically monitors shelf flatness during its normal operations. This eliminates the need for separate manual examination processes, improving efficiency while the sensor unit navigates the narrow space independently
Solution Approach 2:
The rack master is given multi-functionality by integrating the sensor unit, allowing it to perform both its primary function of moving products and the secondary function of examining shelf flatness. This eliminates the need for separate examination equipment or personnel, significantly improving productivity
3Productivity
If shelves are not monitored regularly, then the stocker can operate continuously, but products may be damaged due to inclined or deformed shelves
Solution Approach 1:
The sensor unit provides continuous feedback about shelf flatness to the control system. When shelves become inclined or deformed, the system detects this through displacement measurements and can trigger alerts or corrective actions, ensuring product safety while allowing continuous operation
Solution Approach 2:
The system performs preliminary detection of shelf deformation before it causes product damage. By continuously monitoring shelf flatness during operation, the system can identify and address issues before they lead to product damage, maintaining both productivity and reliability
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
Enables efficient and non-invasive examination of shelf flatness, preventing product damage by ensuring shelves remain horizontal and flat, thus maintaining product quality.
Implementation Method 1
displacement sensors are disposed on a plurality of positions of the facing surface of the sensor unit to measure relative positions between the sensor unit and the shelf at the plurality of positions
Data Source
AI summary
A stocker system and a method of managing a stocker, the stocker system including a stocker, a rack master, and a sensor to easily examine a shelf of the stocker. The stocker includes the shelf on which a product is loaded. The rack master includes a body part and an arm part connected to the body part to move the product toward or away from the stocker. The sensor unit faces the shelf when the arm part is moved above or below the shelf and the sensor unit is disposed on the arm part. The sensor unit includes a facing surface that is not in contact with the arm part. A plurality of displacement sensors is disposed on the facing surface of the sensor unit to measure relative positions between the sensor unit and the shelf at a plurality of positions.