SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT

Abstract

This patent application relates to a new system for automating material handling equipment, whose application is aimed at the handling and movement of loads in industrial, commercial and other environments, for example, vehicles such as forklifts, pallet trucks, tow tractors and AGVs. The invention essentially comprises a control unit (1) that communicates, in two ways, with a display (2), with an impact sensor (3), with a wifi module (4), a locking module (5) and an rfid identification module (6); these devices operate, in a macro way, with a web application module (7) (intranet); a SQL Server database module (8); a Windows service module (9) and, this with the telemetry (10) of the machine (m).

Description

1 / 15 SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT FIELD OF THE INVENTION

[001] This patent application relates to a new system for automating material handling equipment, whose application is focused on the sector of handling and moving loads, for example, forklifts, pallet trucks, tow tractors and AGVs. BACKGROUND OF THE INVENTION

[002] Automation systems based on telemetry are known in the state of the art, and are aimed at various equipment, vehicles and devices that have movements that need to be monitored.

[003] In the specific case of forklifts, there are many operational particularities, given that they are used intensively in industrial or commercial areas, where not only are other machines working, but there are also many physical elements, so that the chance of accidents of greater or lesser magnitude becomes real. STATE OF THE ART

[004] The state-of-the-art document CN106874973, dated 20 / 06 / 2017, which describes a forklift operation monitoring management system based on an electronic compass and a method thereof, is known. The system comprises a vehicle device, a base station, and a communication device. The vehicle device is connected and communicates with the base station via UWB positioning signals. A positioning processor is connected to a monitoring center. The vehicle device comprises a housing and a control circuit in the housing. A front panel of the housing is provided with an electronic compass hole. The control circuit is configured so that a central controller is connected to an electronic compass located in the Petition 870180037604, dated 07 / 05 / 2018, page 4 / 32 2 / 15 front inner surface of the housing and a communication module, and the electronic compass is arranged in the electronic compass hole. The system and its method effectively avoid the disadvantages of the previous technique, which included the possibility of damaged connection points, increased maintenance costs, high software implementation workload, cumbersome information transmission control, inconveniences for users, and poor compatibility.

[005] Document CN105858039, dated 17 / 08 / 2016, describes a method for achieving intelligent storage through an RFID / industrial WIFI technology. The method includes the following steps: first, a central server is deployed in a storage management center, and the intelligent storage system software (one server side) and a storage database are installed; second, a traditional forklift is intelligently transformed based on industrial RFID / WIFI technology; third, an industrial Wi-Fi network covers a warehouse work area, and a stable, reliable, and short-latency industrial WIFI wireless network is placed in a storage area; and fourth, an RFID-based smart tag is placed on a goods storage / packaging location box.The method aligns with the development trend of smart manufacturing and industry. It solves the reliability and stability problems of fast RFID reading and writing in warehouse logistics environments. Furthermore, intelligent warehouse control and management are automatically integrated into system functions, including automatic reading and writing, acoustic-optical advance warning, and similar features. This can increase warehouse utilization rates, reduce labor input, and lower the logistics costs of an entire industry chain, especially in the manufacturing industry. The method is suitable for companies using material handling equipment. Petition 870180037604, dated 07 / 05 / 2018, page 5 / 32 3 / 15

[006] Document CN203255945, dated 10 / 30 / 2013, describes a fork height safety protection device for an electric forklift. The fork height protection device for the electric forklift comprises a detection plate, a sensor mounting plate, a sensor, an electronic control system, and a display. The detection plate is installed to the left of an inner portal, the sensor mounting plate is installed to the left of an outer portal, the sensor is installed on the sensor mounting plate, the detection plate and the sensor are arranged on the same vertical surface, the electronic control system is arranged at the rear of a forklift body, and the display is arranged inside a cabin.The safety protection device for the electric forklift's lifting forks has the advantage that when a fork reaches the set height, automatic speed limit protection is achieved through a fork height detection device and electronic control system software. This prevents the lifting cylinder from rising to its highest position, extending the oil cylinder's service life, improving operating comfort, and enhancing the safety of the electric forklift.

[007] Document CN202886394, dated 17 / 04 / 2013, describes a forklift gantry lifting detection device comprising a distance measuring sensor, a fixing suction cup, a control processor, and a reflective target, wherein the distance measuring sensor is fixed to a forklift via the fixing suction cup; the control processor is connected to the distance measuring sensor; the reflective target is arranged below the forklift in the position corresponding to the distance measuring sensor; and the reflective target is in wireless communication connection with the distance measuring sensor. The forklift gantry lifting speed detection device has the beneficial effects that a set of detection devices integrating optics, electromechanics, computers, and software is designed using a laser distance measurement technique and the Petition 870180037604, dated 07 / 05 / 2018, page 6 / 32 The 4 / 15 device has the advantages of high integration precision, short measurement time, and good stability, as well as the ability to measure multiple items at once. Due to its programming and software design, it performs automatic data processing, automatic calculation of detection results, and automatic generation of velocity curve diagrams.

[008] The devices and systems of the state of the art present, in some of them, solutions aimed at forklifts; however, adding items such as speed control, elevation, distance, so that the solutions are specific to real situations; however, in none of the previous documents analyzed, is a telemetry system presented that can manage all functions, ranging from operator activation to control of operational parameters and even equipment maintenance. OF THE INVENTION

[009] The present invention stands out for presenting an innovative telemetry system that can be divided into four macro parts: - Web Application (Intranet): responsible for maintaining the system's registration and presenting the user with indicators generated by telemetry. It must connect to the database using the server / instance IP address, username, and password; - SQL Server Database: responsible for storing registration and telemetry information. An access user must be created with read and write permissions; - Windows Service: responsible for receiving all types of logs generated by telemetry, storing them in the database, and sending registration data to the machine via synchronization. It must connect to the database using the server's IP address, username, and password. It must connect to the machines using a UDP connection on port 8091; Petition 870180037604, dated 07 / 05 / 2018, page 7 / 32 5 / 15 - Machine Telemetry: responsible for operating the machine. Must connect to the Windows Service using the UDP connection on port 8091, among other activities: a) grant operator access; b) grant access to the mechanic; c) grant supervisor access; d) submit initial checklist; e) Block the machine if it does not comply with the checklist; f) Send events generated by the machine's operation: traction, lifting, impact, usage time, idle time, etc.

[010] In physical terms, the invention comprises a control unit, a display, a Wi-Fi and GPS module, an RFID module, an impact module (fixed to the machine chassis) and a relay / locking module.

[011] In operational terms, the set of boards or modules sends a WiFi signal (or other compatible technology) to the server, which receives this signal and sends information to the designated board; the server then records information from the machine's time bank, such as: login, hour meter, etc.

[012] The information that travels from the forklift to the server sends logs and, in the opposite direction, the forklift receives synchronization; the web application exists on the server (maintains registrations and indicators).

[013] Technically, the machine has a CAN network, which is read by telemetry, in order to establish the condition and intelligence for all machine occurrences to be stored, which are forwarded to the aforementioned server. ADVANTAGES OF THE INVENTION Petition 870180037604, dated 07 / 05 / 2018, page 8 / 32 6 / 15

[014] In addition to those evident from the preceding description, the following advantages can be listed: - control and recording of all incidents involving a forklift or similar vehicle; - control and registration of operators using the equipment; - Negative response if an unauthorized operator attempts to handle the equipment; - Performing a complete checklist when operating the equipment; - Recording of equipment hour meters, allowing for scheduled maintenance; - Recording of impacts, identifying when, where, and with which operator they occurred; - Recording of all operational parameters of the equipment selected by the system; - Blocking the forklift or similar equipment in case of non-compliance with the checklist. DESCRIPTION OF THE DRAWINGS [ 015] The invention will now be described in one embodiment, and for better understanding, reference will be made to the attached drawings, in which are represented: FIGURE 1: General view of the macro diagram of the application of the invention; FIGURE 2: Diagram showing the hardware structure according to the invention; FIGURE 3: Diagram showing the sequence from the system maintenance routine according to the invention; FIGURE 4: Diagram showing the sequence from system initialization according to the invention; Petition 870180037604, dated 07 / 05 / 2018, page 9 / 32 7 / 15 FIGURE 5: Diagram showing the operating mode of the system according to the invention, being: FIGURE 5A: CAN reading; FIGURE 5B: Impact Reading; FIGURE 5C: Maintenance request; FIGURE 6: Diagram showing the system battery reading according to the invention; FIGURE 7: Diagram showing the sequence from the system checklist routine according to the invention; FIGURE 8: Diagram showing the Automatic Synchronization of the system according to the invention, being: FIGURE 8A: General synchronization diagram; FIGURE 9: Diagram showing the sequence from the synchronization of the system according to the invention. DETAILED DESCRIPTION OF THE INVENTION

[016] The SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT, the subject of this Patent Application, comprises a control unit (1) that communicates, in two ways, with a display (2), with an impact sensor (3), with a WiFi module (4), a locking module (5) and an RFID identification module (6). These devices operate, in a macro way, with a Web Application module (7) (Intranet); a SQL Server Database module (8); a Windows Service module (9) and, this with the Telemetry (10) of the Machine (M).

[017] The control unit (1), in one embodiment, includes the MCP2515 processing module + CAN; the touchscreen display (2) can be a 2.4” TFT + processing module; the impact sensor (3) can be a Petition 870180037604, dated 07 / 05 / 2018, page 10 / 32 8 / 15 MPU-6050 accelerometer; the wireless module (4) + GPS can be an ESP8266 or GPS - NEO6M; the locking module (5) can be a CTK 05V relay and the RFID identification module (6) + biometrics can be an MFRC522.

[018] Figure 1 shows the macro diagram of the application, where the Web application module (7) (Intranet) is responsible for maintaining the system registration and presenting the user with indicators generated by telemetry. It must connect to the database (8) via the server IP, instance, username and password.

[019] The Database (8) is, in one embodiment, a SQL Server, responsible for storing registration and telemetry information. An access user must be created with read and write permissions.

[020] The Windows Service module (9) is responsible for receiving all types of logs generated by telemetry, storing them in the database (8) and sending the registration data via synchronization to the forklift-type machine (M). The Windows Service module (9) must connect to the database module (8) via the IP of the instance server, username and password. Preferably, the connection to the machines should be made using UDP port 8091.

[021] The Telemetry (10) of the Machine (M) is responsible for the operation of said machine (M), and must connect the Windows Service module (9) using the UDP connection port 8091, having the following functions: - Grant operator access; - Grant the mechanic access; - Present the initial checklist; - Block machine (M) in case of non-compliance in the checklist; - Send events generated by the machine operation (M): traction, lifting, impact, usage time, idle time, etc. Petition 870180037604, dated 07 / 05 / 2018, page 11 / 32 9 / 15

[022] Also according to Figure 1, the machine (M), which has a CAN network, sends the machine log (LO) to the Windows Service module (9) and this sends the 'write log' command (GL) to the database module (8), which transfers indicators (IN) to the Web module (7), which returns the 'synchronization registration' (CS) to the database module (8) and this the information 'read synchronization data' (LDS) to the Windows Service module (9), from where the 'synchronize' command (SI) goes to the telemetry (10) of the machine (M).

[023] Figure 4 shows the system initialization sequence according to the invention, where 'initialization' (11) triggers 'peripheral initialization' (12) followed by the 'lock machine by relay' operation (13), succeeded by 'synchronization' (14) which 'enables automatic synchronization' (15), prompting the question: 'Is the machine in lock mode?' (16). If the answer is negative, the 'identification screen' (17) is activated, which asks if 'it is at the base?' (18). If the answer is negative, it triggers the 'error warning and sends log' (19). If the answer is positive, it goes to the question of 'is it mechanical?' (20), that is, if the person is a mechanic; with the negative answer, one goes to the question 'is it the same badge as the last login' (21)?; with the negative answer one goes to the 'checklist routine' (22); with the positive answer, one goes to the 'operating mode' (23).

[024] In the block 'is it mechanical?' (20), a positive answer leads to the question 'perform maintenance?' (24); if negative, go to 'operating mode' (23); if positive, go to 'maintenance routine' (25).

[025] In the block “Is the machine in lock mode?” (16) if the answer is positive, it goes to the “lock screen” (26) which “waits for card reading” (27) asking if “it is at the base?” (28); if the answer is negative, an “error message and log sending” occurs (29). If the answer is positive again, the question “is it mechanical?” (30) occurs; if the answer is positive, the “maintenance routine” (25) follows. If the answer is negative, another question occurs “is it supervisor?” (31); if the answer is positive, it leads to the “checklist routine” (22); the answer Petition 870180037604, dated 07 / 05 / 2018, page 12 / 32 10 / 15 negative generates 'error message' (32) and sends communication to the 'lock screen' (26).

[026] Figure 7 shows the 'checklist routine' (22), which triggers the 'unlock the machine' (33), generating the question 'did the operator turn on the machine' (34); a negative answer leads to the 'identification screen' (17); a positive answer causes the system to 'show a checklist question' (35) which generates the question 'did a timeout occur?' (36); a positive answer leads to the 'identification screen' (17); a negative answer generates another question 'was the question answered correctly?' (37). A positive answer leads to the question 'was the last question answered?' (38); if negative, it returns to the 'show a checklist question' block (35); if positive, it goes to the 'operation mode' (23).

[027] If the answer in (37) is negative, the question 'is a logged-in supervisor?' appears (39); if negative, a 'blocking log' (40) is generated and sent to the 'blocking screen' (26). If the answer is positive, the question 'do you want to ignore the non-conformity?' is generated (41); if negative, the 'blocking log' (40) is generated; if positive, the question 'was the last question answered?' (42) is generated; if positive, the 'non-conformity log' (43) is generated and passed to the 'operation mode' (23); if negative, the 'non-conformity log' (43) is directed to the 'show a checklist question' block (35).

[028] Figure 5 shows the system operating mode according to the invention, wherein all independent blocks in this mode work waiting for an interruption event, except for reading the CAN network.

[029] FIGURE 5A shows the 'CAN reading' (44) which triggers the 'read speed' block (45) which 'shows the speed on the screen' (46) generating the question 'exceeded the speed limit?' (47); if yes, 'shows a warning screen' (48); if no, goes to the 'read other CAN data' block (49) generating the question 'was there any new event?' (50); if Petition 870180037604, dated 07 / 05 / 2018, page 13 / 32 11 / 15 negative return to CAN reading block (44); positive if generates the question 'is the machine connected to the network?' (51); negative if 'save to EPROM' (52); positive if 'send compliance logs' (53).

[030] FIGURE 5B from the 'impact reading' (54) generates the question 'is the machine connected to the network?' (55); if yes, 'sends impact log' (56); if no, 'saves to EPROM' (52).

[031] FIGURE 5C starts with the 'maintenance request' block (57) moving on to the 'lock the machine' block (58) generating the question 'is the machine connected to the network?' (51), with the possibilities of 'send maintenance log' (59), 'lock screen' (60) and 'save to EPROM' (52).

[032] FIGURE 8 describes the automatic synchronization mode, that is, from the 'automatic synchronization' block (61) it generates the question 'are there still logs in the queue?' (62); if negative it goes to the 'wait a while' block (63); if positive, it generates the question 'are there still many logs to be sent?' (64); if positive 'wait a while' (63); if negative it generates the question 'is the machine connected to the network?' (65); the negative answer leads to 'wait a while' (63); the positive answer 'sends logs one by one' (66) then going to the 'are there still logs in the queue?' block (62). Therefore, in general terms, according to FIGURE 6A, when 'receiving some update from the server' (67) 'synchronization' (68) occurs and, once completed, the 'end' command (69) is given.

[033] FIGURE 9 shows the system synchronization system according to the invention, where 'synchronization' (68) goes to the 'interface service connection attempt' block (70) generating the question 'connected?' (71); if negative it generates the question 'extend connection time?' (72); in another negative it returns to the 'interface service connection attempt' (70); if positive it goes to the 'ignore synchronization and continue from the process where it stopped' block (73).

[034] If 'connected' (71) has a positive response, it generates the question 'is there data to be synchronized?' (74); if the response is negative, it goes to Petition 870180037604, dated 07 / 05 / 2018, page 14 / 32 12 / 15 block 'time synchronization' (75) generating the question 'success?' (76); if positive it is the 'end of synchronization' (77); if negative it generates the question 'extend connection time?' (72); negative answer returns to 'time synchronization' (75); positive answer goes to the block 'ignore synchronization and continue from the process where it stopped' (73).

[035] If the block 'is there data to be synchronized?' (74) has a positive response, it goes to the block 'requests data from the server' (78) generating the question 'success?' (79); if the response is negative, it asks if 'connection lost?' (80); if negative, it returns to 'requests data from the server' (78); if positive, it returns to the block 'ignores synchronization and continues from the process where it stopped' (73). If the block 'success?' (79) has a positive response, the question 'is there still data to be synchronized?' (81) occurs; positive response 'requests data from the server' (78); negative response 'end of synchronization' (77).

[036] FIGURE 3 shows the system maintenance routine according to the invention, where the 'maintenance routine' block (82) is followed by the 'unlock machine' block (83) generating the question 'has maintenance already started?' (84); if negative, 'send maintenance start log' (85) is sent and the 'maintenance checklist' (86) is performed which goes to the 'await maintenance end' block (87), which is also accessed if the answer in (84) is positive. Following this is the 'end confirmation' block (88) which 'sends maintenance end log' (89), then 'sends hour meter log' (90), until the 'maintenance end' (91) is reached, when it 'returns to the identification screen' (17).

[037] FIGURE 6 shows the Battery Reading according to the invention system, where it 'waits 1 minute' (92) to 'read the battery information' (93) generating the question 'was there a significant change?' (94), if negative it returns to 'wait 1 minute' (92) and, if positive, 'saves to EPROM' (95) and sends a command to 'wait 1 minute' (92). Then 'logoff' occurs. Petition 870180037604, dated 07 / 05 / 2018, page 15 / 32 13 / 15 (96) the question 'is the machine connected to the network?' (97) is generated; if not, 'save to EPROM' (95) and send to the 'identification screen' (17). If yes, 'logoff log' (98) is sent, then 'battery log' (99) and 'hour meter log' (100) are sent, in addition to 'queue logs' (101) being sent, communicating to the 'identification screen' (17).

[038] Technically, the system allows many modes of control and automation of a machine (M), and others may be created from the telemetry resources presented here, which essentially combine the modules presented here with the CAN network of the machine (M) and the resources of a described software to perform the various operations.

[039] As an example, each machine operator (M) has a badge through which the said operator is linked to the equipment that he or she can operate. Thus, when synchronization occurs, the telemetry (10) receives from the system which operators are qualified to operate the machine (M).

[040] In synchronization, other parameters are also received, such as: - impact parameters: monitors collision on or of the equipment, allowing assessment via telemetry (10) of whether the impact is classified as light, medium or severe; - Sensors in the X, Y, and Z directions, in order to register the presence of holes, among other things; - In the most critical areas, the impact parameters may vary depending on the location, for example.

[041] Another aspect already addressed in the diagrams above deserves a more didactic description for better understanding. In the checklist process, the operator identifies himself; if he is registered, the machine starts; if it is not the machine in question (M), it will not start. Petition 870180037604, dated 07 / 05 / 2018, page 16 / 32 14 / 15

[042] In this process, as already recorded, questions are asked to be answered by the operator within a predetermined time. If these answers are not provided, the machine (M) locks and returns to the identification screen (17). Once the questions are finished, the operating mode is entered (23).

[043] Another aspect to be highlighted is that, when the operator turns off the machine (M), the telemetry (10) turns off after a certain time. Thus, to operate the machine again, the operator needs a new identification.

[044] In other words, if the operator stops and returns again, with their identification confirmed, they do not need to do the checklist again; instead, they go directly to the operating mode screen.

[045] Therefore, the present invention allows monitoring of everything that is happening with the machine (M), such as: operating time, whether the operator is in his seat, whether the handbrake is engaged, whether the operator is wearing the seatbelt. Evidently, for this purpose sensors are used that communicate with the telemetry (10) which triggers the procedures described.

[046] The present invention also has some differentiating and innovative features, such as the use of quick connectors, which makes maintenance faster; use of a processing module; it includes an adaptation shield - modular structure - where one board allows the adaptation of several other boards.

[047] Other possibilities are foreseen, such as placing sensors in the machine's own structure (M); furthermore, a possible collision can be identified by light and / or sound signals, and it is also possible that telemetry (10) will indicate which sensor registered the collision, identifying the location of the machine. This can be very positive in equipment or locations where collisions become recurrent. Petition 870180037604, dated 07 / 05 / 2018, page 17 / 32 15 / 15

[048] For example, if a collision occurs in a specific area, identified by the system, the machines operating in that area can be stopped, so that only the supervisor, with justification, can unlock them.

[049] Another characteristic already addressed in the previous diagrams, very important for the useful life of a machine (M), refers to the location and control of the machine's hour meters (M), that is, with the evolution of said hour meters it is possible to plan maintenance, via map; in addition to creating equipment maintenance plans (example: 50 hs, 100 hs, 200 hs, 500 hs, etc.)

[050] It is also possible to determine item by item to be checked, with the determination of the start and end of maintenance, in order to standardize maintenance. Petition 870180037604, dated 07 / 05 / 2018, page 18 / 32

Claims

1 / 2 CLAIMS 1 - SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT, of the type comprising a bidirectional communication architecture between a machine (M) equipped with a CAN network and remote application and database modules, with transmission of operational data, logs and telemetry information, characterized by a control center (1) including a processing module + CAN, which communicates, in two ways, with a display (2) + processing module, with an impact sensor (3), with a wireless module (4), a locking module (5) and an RFID identification module (6) + biometrics; these devices operate, in a macro way, with a Web application module (7) (Intranet); a relational database module (8);operating system service module (9) and, this, with the telemetry (10) of the machine (M), the telemetry (10) being responsible for authorizing, conditioning and controlling the operation of the machine (M), for releasing operator and mechanic access, for presenting the initial checklist, for blocking the machine (M) in case of non-compliance and for sending events generated by the operation of the machine (M), wherein the machine (M) has a CAN network that sends 'machine log' (LO) to the operating system service module (9) and this sends a 'write log' command (GL) to the relational database module (8), which transfers indicators (IN) to the Web application module (7), which returns the 'synchronization registration' (CS) to the relational database module (8) and this the information 'read synchronization data' (LDS) to the operating system service module (9), from where the 'synchronize' command (SI) goes to the telemetry (10) of the machine (M);the operating system service module (9) receives the logs generated by the telemetry (10), promotes storage in the relational database module (8) and sends the registration data through synchronization processes to the machine (M), connecting to said database through authentication and server addressing parameters; and the telemetry (10) of the machine (M) connects to the operating system service module (9) Petition 870260049784, dated 05 / 25 / 2026, page 24 / 28; 2 / 2 via network communication protocol, having the following functions: granting operator access; granting mechanic access; presenting the initial checklist; blocking the machine (M) in case of non-compliance with the checklist; and sending events generated by the machine's operation (M), including at least traction, lifting, impact, usage time, downtime, and related events. 2 - SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT, according to claim 1, characterized by the Web application module (7) - Intranet - being responsible for maintaining the system's registration and presenting the user with indicators generated by telemetry, connecting to the relational database module (8) through authentication parameters and server addressing. 3 - SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT, according to claim 1, characterized in that the relational database module (8) is responsible for storing the system's registration and telemetry information. 4 - SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT, according to claim 1, characterized by. 5 - SYSTEM FOR AUTOMATING MATERIAL HANDLING EQUIPMENT, according to claims 1 to 6, characterized by the system operating machine control and automation modes (M), which combine the described modules with the machine's CAN network (M) and with software resources intended for the execution of the respective operations. Petition 870260049784, dated 05 / 25 / 2026, pp. 25 / 28

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