Wireless Safety Interlock for Robotic Grid Storage Access
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Solution Overview
Problem
Existing automated storage and picking systems face challenges in maximizing storage density and accessibility while ensuring safe operation, particularly in large-scale systems with numerous robotic load handling devices that can cause injury during maintenance or emergencies.
Innovation Solution
A safety system comprising a transmitter and receiver circuitry that interrupts power to load handling devices upon detection of unauthorized access or emergencies, using a programmable logic controller to ensure all devices are safely stopped before access points are opened.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multi-product stacks are used to maximize storage density, then storage efficiency is improved, but accessibility and picking speed of items may be reduced
Solution Approach 1:
The system dynamically reconfigures stack compositions based on picking frequency and urgency. High-priority items are automatically positioned in upper container positions for faster access, while lower-priority items are placed in lower positions. This dynamic optimization allows the system to maintain high storage density while minimizing picking time for frequently ordered items.
Solution Approach 2:
The control system continuously monitors picking patterns and item priority levels, using this feedback to optimize stack configurations. When an item is frequently picked or has high priority, the system automatically adjusts the stack arrangement to place that item in more accessible positions, thereby reducing picking time without sacrificing overall storage density.
2Productivity
If load handling devices operate at high speed to improve productivity, then system efficiency is improved, but safety risks during maintenance or emergencies increase
Solution Approach 1:
A wireless communication system acts as an intermediary between the control system and load handling devices. The transmitter continuously sends safety signals to receivers on each device, enabling rapid communication of emergency stop commands throughout the system without mechanical intervention, thus maintaining high operational speed while enabling quick safety responses.
Solution Approach 2:
The system continuously transmits safety signals and maintains readiness to issue emergency stop commands before actual emergencies occur. Load handling devices are pre-configured with receivers that can immediately receive and respond to stop signals, ensuring that when maintenance or emergencies occur, the system can rapidly shut down all devices regardless of their operational state.
3Ease of operation
If access points are opened during operation to improve maintenance accessibility, then ease of operation is improved, but risk of contact with moving devices increases
Solution Approach 1:
The system applies preliminary anti-action by continuously monitoring access point status and pre-emptively issuing emergency stop commands when access points are opened or should be opened. The transmitter detects access point opening and immediately transmits stop signals to all load handling devices, preventing any moving device from entering the access area and eliminating the risk of contact between personnel and moving equipment.
Data Source
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AI summary
A safety system for an automated storage and picking system is described. The storage system includes load handling devices operating above a series of stacked containers, the stacked containers (10) being located within a framework, the top of which comprises tracks on which the load handling devices (30) operate. The safety system includes a transmitter located in close proximity to the storage system and a receiver located on each of the load handling devices. The transmitter continually transmits a signal that is detected by the receivers on the load handling devices (30). In the event of an emergency or a breach of the storage system, the transmission of the signal is cut. Once the receiver no longer receives the signal from the transmitter, power to the drive means of the load handling device (30) is cut and the storage system is rendered safe.