Automated Storage Vehicle Detection Assembly for Overhanging Items
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Solution Overview
Problem
Existing material handling systems face challenges in efficiently conveying items without overhanging or extending beyond predetermined dimensional thresholds, which can lead to damage or injury, and require manual labor for sorting and retrieving, making them laborious and costly.
Innovation Solution
A material handling system with a detection assembly that uses a light emitter and imaging element to create a 3D representation of the target area, detecting items that extend beyond a predetermined threshold and controlling vehicle movement to prevent over-height conditions and ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated conveying systems are used to reduce labor costs and improve efficiency, then productivity increases, but safety hazards arise when items overhang or extend beyond dimensional thresholds
Solution Approach 1:
The detection assembly performs preliminary detection of item dimensions before the vehicle completes its cycle. The system identifies overhanging or over-height items in advance, allowing preventive actions (stopping the vehicle, alerting operators) to be taken before hazards materialize, thus maintaining automated efficiency while preventing safety incidents
Solution Approach 2:
The detection assembly acts as an intermediary between the automated conveying system and safety control. It monitors item dimensions and communicates with the controller to mediate between automated operation and safety requirements, enabling the system to adjust vehicle movement based on detected dimensional constraints
2Object-affected harmful factors
If detection assemblies are added to monitor item dimensions, then safety is improved, but device complexity increases
Solution Approach 1:
The detection assembly is designed to perform multiple functions: detecting overhanging items, detecting over-height items, and providing data for vehicle control decisions. This multi-functionality reduces the need for separate detection systems for different hazard types, thereby limiting the increase in device complexity while comprehensively addressing safety concerns
Solution Approach 2:
The system replaces complex mechanical dimensioning devices with optical or electromagnetic detection methods. The detection assembly uses non-contact sensing to measure item dimensions, substituting mechanical measurement systems with simpler, more reliable sensor-based detection that reduces overall system complexity
3Measurement precision
If vehicles are stopped frequently to check item dimensions, then measurement precision improves, but productivity decreases
Solution Approach 1:
The detection assembly operates continuously as vehicles pass through the monitoring zone, eliminating the need to stop vehicles for dimension checks. The system maintains continuous detection capability, ensuring measurement precision is achieved through sustained observation rather than intermittent sampling, thereby preserving vehicle throughput and productivity
Solution Approach 2:
The system transitions from time-based detection (stopping and checking) to space-based detection (continuous monitoring along the vehicle path). By positioning the detection assembly to scan items in the spatial dimension as vehicles move through the zone, the system achieves precise dimensional measurement without interrupting vehicle motion, thus maintaining productivity
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
The system effectively prevents items from exceeding dimensional constraints, reducing the risk of damage or injury and automating the sorting and retrieval process, thereby improving efficiency and safety while minimizing labor costs.
Implementation Method 1
an emitter for projecting a light source onto one of the vehicles when the vehicle is at a location along the path. The detection assembly may also include an imaging element configured to detect the light projected onto the vehicle.
Data Source
AI summary
A method and apparatus are provided for sorting or retrieving items to/from a plurality of destinations areas. The items are loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles follow a path to/from the destination areas that are positioned along the path. Along the path, the vehicles are scanned to determine if any item on the vehicles extends beyond a dimensional constraint. If it is determined that an item on a vehicle extends above the pre-determined threshold, the vehicle is controlled, such as by stopping or re-directing the vehicle. Once at the appropriate destination area, an item is transferred between the delivery vehicle and the destination area.