Skip to main content
Racks in an automated high-bay warehouse can shift or deform after long-term use and changing loads. During high-level stacker-crane operations, an abnormal pallet, rack, or storage location can cause docking errors, jams, or downtime. This solution captures the site state with 3D perception and reports exceptions to the control system.
3D vision monitoring pallet and rack status in an automated warehouse

​
Solution overview

3D vision sensors capture pallet, rack, and storage-location data to identify position, shape, offset, tilt, and deformation. When an exception is detected, the system can send the result to the stacker-crane controller so it can pause operation, raise an alarm, or execute another configured action.

​
Detection tasks

  • Pallet-status monitoring: Detect pallet offset, tilt, or deformation to help prevent interference between the stacker crane and the load.
  • Rack-structure monitoring: Detect movement or deformation of beams and uprights to support equipment-status assessment.
  • Storage-location occupancy: Confirm whether a load unit is present and help prevent incorrect put-away or retrieval.

​
Solution characteristics

  • 3D position data: Capture spatial position and shape instead of only a 2D location.
  • Less site modification: No holes or reference points are required on the rack; confirm the installation method against the site structure.
  • Ambient-light adaptation: Active illumination is used to capture depth data.
  • System integration: Connect to stacker-crane or host-control systems through I/O, CAN, Ethernet, or TCP/IP.
  • Non-standard applications: Configure the solution for non-standard pallets or special storage locations.