TL;DR
Repeated false stops in the same location usually mean a dirty safety scanner or a highly reflective surface (shrink wrap, chrome rack label) creating a phantom return. Clean the scanner and identify nearby reflectors.
What you might see
- robot stopping repeatedly in the same aisle location with no visible obstacle
- safety scanner fault alarm on the fleet console
- robot throughput declining due to excessive false stops
- safety scan zone event logged in the absence of any person or object in the path
Likely causes
Dirty safety laser scanner window scattering its own beam and registering a false detection
Highly reflective surfaces (shrink-wrapped pallets, mirror-finish racking) creating back-scatter detections inside the safety zone
Floor level debris (small cardboard pieces, stretch film) within the scan zone height triggering a stop
Safety zone configuration tuned too conservatively for the actual aisle dimensions
Required tools
- Fleet management console for event log and scan zone diagnostic
- Lint-free cloth for scanner window cleaning
Safety first
- Safety laser scanners are safety-critical devices. Do not adjust scan zone boundaries without a formal risk assessment and site safety approval.
- When performing any close-range inspection in an active AMR aisle, alert warehouse personnel and ensure the aisle is clear before working at floor level.
Procedure
- 1
Note the location and direction of the false stop from the fleet console log. If it always happens at the same location, a local environment factor is responsible.[1]
- 2
Inspect the safety scanner window on the robot at the reported stop location. Clean the window with a dry lint-free cloth.
Warning: Safety laser scanners are safety-rated devices. Do not modify scan zone configurations without completing a safety risk assessment and following the change-control procedure for your site. Reducing a safety zone boundary without authorization can endanger personnel. - 3
Walk the aisle at the false-stop location and look for highly reflective surfaces near floor level: silver pallet labels, chrome rack legs, or low-slung shrink wrap. Mask or reposition any identified reflector.
- 4
Inspect the floor in the false-stop area for small debris at scanner height. Clear any debris from the path.
- 5
Check the safety scanner diagnostic data from the fleet console to identify which scan zone segment triggered the stop. This narrows the physical search area.
- 6
If reflectors have been addressed and false stops continue, submit a scan zone review request to the system integrator or OEM, with the logged event data attached.
Sources
Locus Robotics Locus Origin AGV / AMR (Mobile Robots) general technical documentation, Locus Robotics
AMR safety scanner maintenance, false positive detection troubleshooting, general material handling references (general)
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