A method for constructing a digital twin of a forklift based on a flight control system

Abstract

The present invention relates to a method for constructing a digital twin of a forklift based on a flight control system, comprising the following steps: importing a three-dimensional model, an electrical model and a hydraulic model into simulation software to establish a digital twin of a forklift; obtaining the operation data of the forklift through a flight control system and a plurality of sensors; exporting the digital twin of the forklift from the simulation software to generate a digital twin application; writing the real-time operation data of the forklift into a parameter file of the digital twin through a ground station of the flight control system; running the digital twin application, loading the parameter file, and generating a result file; obtaining a recommended value of the driving speed of the forklift's existing lifting weight according to an evaluation report and a result file. The present invention prevents the occurrence of dangerous accidents without reducing the transportation efficiency of the forklift by constructing a digital twin of a forklift, running the digital twin application, generating a result file, obtaining a recommended value of the driving speed of the forklift's existing lifting weight according to an evaluation report and a result file, and predicting overturning, thereby preventing the occurrence of dangerous accidents.

Description

Technical Field

[0001] The present invention belongs to the technical field of forklift equipment, and in particular relates to a forklift digital twin construction method based on a flight control system. Background Art

[0002] As a general-purpose technology that promotes the Fourth Industrial Revolution, digital twins can achieve data-driven operational monitoring and optimization by deeply integrating the physical world and digital space, combined with intelligent algorithms, greatly promoting the development of the manufacturing industry towards a higher level of automation, informatization, and intelligence. Digital twins are a simulation process that integrates multiple disciplines, multiple physical quantities, multiple scales, and multiple probabilities, and completes mapping in virtual space, thereby reflecting the entire life cycle of the corresponding physical equipment.

[0003] In recent years, the scale of the logistics industry has grown rapidly, service capabilities have been significantly improved, and technical equipment conditions have been significantly improved. Logistics equipment has shown several major trends such as large-scale, complex functions, and efficient capabilities. Among them, forklifts are transport vehicles that have the load-carrying and transporting functions of automobiles and can realize mechanized loading and unloading. They are practical and efficient and play a vital role in the logistics industry. However, improper use of forklifts, such as excessive speed, has caused safety accidents, resulting in major casualties and serious economic losses. Summary of the invention

[0004] The object of the present invention is to provide a forklift digital twin construction method based on a flight control system, which can provide a recommended value for driving speed, so that the vehicle speed is within the recommended speed and ensure the safety of the driver;

[0005] In order to achieve the above object, the technical solution adopted by the present invention is:

[0006] A method for constructing a forklift digital twin based on a flight control system includes the following steps:

[0007] Build a 3D model of forklift parts, and import the 3D model, electrical model, and hydraulic model into the simulation software to create a digital twin of the forklift;

[0008] The operation data of the forklift is obtained through the flight control system and multiple sensors, and stored as historical data;

[0009] The acceleration in the historical data is added as inertial force to the forklift digital twin through simulation software;

[0010] Export the forklift digital twin to the simulation software, generate the digital twin application and parameter files, and then import them into the forklift’s onboard computer;

[0011] The real-time operation data of the forklift is written into the parameter file of the digital twin through the ground station of the flight control system;

[0012] Run the digital twin application, load the parameter file, and generate the result file;

[0013] The driver's turning and braking operating habits and road conditions are evaluated based on historical data to obtain an evaluation report; the recommended value of the driving speed of the forklift's current lifting weight is obtained based on the evaluation report and result file.

[0014] Preferably, the method further comprises the following steps:

[0015] The forklift motor speed is controlled by the forklift controller to keep the forklift speed within the recommended speed, and the recommended speed is announced by the voice prompt device.

[0016] Preferably, the method further comprises the following steps:

[0017] Predict whether the forklift will overturn based on the assessment report and result documents, and provide the driver with a voice prompt device to warn of the overturning.

[0018] Preferably, the forklift digital twin includes a forklift lifting mechanism, a steering mechanism, a gantry system, a hydraulic system, and an electrical model constructed by three-dimensional drawing software.

[0019] Preferably, the flight control system is a UAV flight control system; the flight control system includes a gyroscope, an accelerometer and a GPS, the gyroscope is used to detect the tilt angle of the forklift body, the accelerometer is used to obtain the body speed and body impact acceleration, and the GPS is used to locate the forklift position.

[0020] Preferably, the multiple sensors include a lifting cylinder displacement sensor, a tilt cylinder displacement sensor and a weight sensor; the lifting cylinder displacement sensor and the tilt cylinder displacement sensor are used to detect the extension distances of the lifting cylinder and the tilt cylinder respectively; the weight sensor is used to detect the weight of the heavy object on the fork frame.

[0021] Preferably, the display screen of the onboard computer dynamically displays the real-time three-dimensional posture and operation data of the forklift.

[0022] Preferably, the flight control system is any one of an APM flight control system, a PX4 flight control system or a PIX flight control system.

[0023] Preferably, the ground station is an open source ground station that matches the flight control system, which is one of the mission planner ground station and the QgroundControl ground station.

[0024] The present invention constructs a digital twin of a forklift through three-dimensional software and simulation software, collects the operating data of the forklift through a flight control system and multiple sensors, runs a digital twin application, generates a result file, obtains a recommended driving speed for the forklift's existing lifting weight and predicts overturning based on an evaluation report and the result file, and uses a controller to make the forklift's maximum driving speed below the recommended driving speed, thereby preventing the occurrence of dangerous accidents without reducing the forklift's transportation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the structure of a forklift of the present invention;

[0026] Figure 2 This is a schematic diagram of the process structure of a forklift digital twin construction method based on a flight control system of the present invention. DETAILED DESCRIPTION

[0027] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0028] The present invention provides a forklift digital twin construction method based on a flight control system, which is used to construct a forklift digital twin, thereby obtaining a recommended value of the forklift driving speed;

[0029] like Figure 1 As shown, the forklift includes a flight control system 1, a tilt cylinder displacement sensor 2, a weight sensor 3, a lifting cylinder displacement sensor 4 and an onboard computer 5; the flight control system 1 is horizontally installed under the chassis of the forklift; the tilt cylinder displacement sensor 2 is installed on the tilt cylinder of the forklift, and is used to measure the extended length of the tilt cylinder, so as to detect the tilt degree of the forklift fork; the weight sensor 3 is installed in the forklift door frame, and detects the weight of the heavy object on the fork by detecting the tension of the forklift chain; the lifting cylinder displacement sensor 4 is installed on the forklift door frame, and is used to detect the extended length of the lifting cylinder, so as to detect the height of the forklift fork; the onboard computer 5 is installed in the cab of the forklift facing the driving position, and is used to collect data measured by various detection devices, and then perform stability judgment calculations, and present the real-time dynamic picture of the forklift posture through the digital twin; the onboard computer 5 is electrically connected to the flight control system 1, the tilt cylinder sensor, the weight sensor 3 and the lifting cylinder displacement sensor 4, wherein the flight control system 1 can be connected to the onboard computer 5 via a USB cable;

[0030] like Figure 2 As shown in the figure, the specific construction method of the forklift digital twin includes the following steps:

[0031] S1. Build a three-dimensional model of forklift parts, and import the three-dimensional model, electrical model and hydraulic model into the simulation software to establish a digital twin of the forklift;

[0032] Among them, the 3D model of forklift parts is constructed through 3D software. The hydraulic model refers to the hydraulic component model used to establish the matching between the tilt cylinder and the lifting cylinder and the real object, so as to build the digital twin of the forklift hydraulic system.

[0033] Specifically, the 3D model, electrical model and hydraulic model are imported into the Simulation X multidisciplinary simulation software to establish the digital twin of the forklift.

[0034] S2, obtaining the operation data of the forklift through the flight control system 1 and multiple sensors, and storing it as historical data;

[0035] The flight control system 1 is a UAV flight control system; the flight control system 1 is any one of an APM flight control system, a PX4 flight control system, or a PIX flight control system; the flight control system 1 includes a gyroscope, an accelerometer, and a GPS, wherein the gyroscope is used to detect the tilt angle of the forklift body, and the accelerometer is used to obtain the body speed and the body impact acceleration, wherein the body impact acceleration is the impact acceleration caused by the tilt angle, turning, or bumping of the forklift body; the GPS is used to locate the forklift position, so as to facilitate recording the forklift route;

[0036] Among them, the flight control system 1 is an existing technology and an open source system with low cost. It integrates the detection of acceleration, inclination and positioning, which is convenient for building a forklift digital twin;

[0037] The multiple sensors include a lifting cylinder displacement sensor 4, a tilting cylinder displacement sensor 2 and a weight sensor 3; the lifting cylinder displacement sensor 4 and the tilting cylinder displacement sensor 2 are used to detect the extension distance of the lifting cylinder and the tilting cylinder respectively; the weight sensor 3 is used to detect the weight of the heavy object on the fork frame;

[0038] The historical data refers to the data obtained through the flight control system 1 and multiple sensors after the forklift has been running for a period of time;

[0039] S3. Add the acceleration in the historical data as inertial force to the forklift digital twin through simulation software;

[0040] Specifically, the acceleration in the historical data is used as inertial force and added to the forklift digital twin through the Simulation X simulation software;

[0041] S4, exporting the forklift digital twin to the simulation software, generating a digital twin application and parameter file, and then importing them into the forklift's onboard computer 5;

[0042] Specifically, the forklift digital twin is exported to the Simulation X simulation software and exported into an exe type digital twin and parameter file; and then imported into the onboard computer 5 of the forklift;

[0043] S5. Write the real-time operation data of the forklift into the parameter file of the digital twin through the ground station of the flight control system 1;

[0044] The ground station development software is installed in the onboard computer 5, and the ground station obtains the real-time operation data of the forklift through the flight control system 1 and multiple sensors, and writes it into the parameter file obtained in step S4;

[0045] The ground station is an open source ground station that matches the flight control system 1, which is one of the mission planner ground station and the Qgroun dControl ground station;

[0046] S6. Run the digital twin application, load the parameter file, and generate the result file;

[0047] Specifically, the digital twin application is run by the onboard computer 5, and the parameter file obtained in step S5 is automatically loaded after the running, and the digital twin is performed. After the completion, a result file is generated, and the generated result file is the real-time operating status of the forklift;

[0048] S7. Evaluate the driver's turning and braking operating habits and road conditions based on historical data to obtain an evaluation report; obtain the recommended value of the driving speed of the forklift's current lifting weight based on the evaluation report and result file.

[0049] Most forklifts transport goods back and forth, and their operation trajectories are repeated many times. Through historical data, the actions of the next operation are evaluated by referring to historical driving records. For example, if the maximum impact acceleration occurs at a certain position in the historical records, the driving speed should be reduced when it comes to this position again.

[0050] The optimal driving speed of the forklift with the weight of the load on the forks is calculated by the onboard computer 5 according to the evaluation report and the result file, and the recommended driving speed is continuously adjusted when the driver turns and the road condition changes.

[0051] In this embodiment, the following steps are also included:

[0052] S8. Control the motor speed of the forklift through the forklift controller to keep the forklift speed within the recommended speed, and announce the recommended speed through the voice prompt device;

[0053] Specifically, the onboard computer 5 is electrically connected to the forklift controller, and the onboard computer 5 transmits the recommended driving speed signal to the forklift controller. The forklift controller controls the speed of the forklift motor to control the forklift speed within the recommended speed. The onboard computer 5 is also electrically connected to the voice prompt device, and the current road conditions and the recommended speed under the current weight are broadcast to the driver through the voice prompt device.

[0054] In this embodiment, the following steps are also included:

[0055] S9. Predict whether the forklift will overturn based on the assessment report and result documents, and give the driver a warning of overturning through a voice prompt device;

[0056] Specifically, through the historical data of the driving speed record under the weight of the load on the fork, it is evaluated to prevent the forklift from overturning due to excessive speed during the next operation. For example, the weight of the load on the fork of the forklift is 1 ton, and the forklift is driving at a speed of 15 miles. When the weight of the load on the fork of the fork next time is 2 tons or heavier, if the forklift is still driving at a speed of 15 miles, it may cause overturning; the onboard computer 5 warns the driver of the overturning through the voice prompt device.

[0057] In this embodiment, the display screen of the onboard computer 5 dynamically displays the real-time three-dimensional posture and operation data of the forklift, which is convenient for the driver to observe and adjust the driving speed in real time to prevent accidents.

Claims

1. A forklift digital twin construction method based on a flight control system, characterized in that: The following steps are involved: Build a 3D model of forklift parts, and import the 3D model, electrical model, and hydraulic model into the simulation software to create a digital twin of the forklift; The operation data of the forklift is obtained through the flight control system and multiple sensors, and stored as historical data; The acceleration in the historical data is added as inertial force to the forklift digital twin through simulation software; Export the forklift digital twin to the simulation software, generate the digital twin application and parameter files, and then import them into the forklift’s onboard computer; The real-time operation data of the forklift is written into the parameter file of the digital twin through the ground station of the flight control system; Run the digital twin application, load the parameter file, and generate the result file; The driver's turning and braking operating habits and road conditions are evaluated based on historical data to obtain an evaluation report; the recommended value of the driving speed of the forklift's current lifting weight is obtained based on the evaluation report and result file.

2. According to claim 1, a forklift digital twin construction method based on a flight control system is characterized in that: The following steps are also included: The forklift motor speed is controlled by the forklift controller to keep the forklift speed within the recommended speed, and the recommended speed is announced by the voice prompt device.

3. The method for constructing a forklift digital twin based on a flight control system according to claim 1, characterized in that: The following steps are also included: Predict whether the forklift will overturn based on the assessment report and result documents, and provide the driver with a voice prompt device to warn of the overturning.

4. The method for constructing a forklift digital twin based on a flight control system according to claim 1, characterized in that: The forklift digital twin includes a forklift lifting mechanism, a steering mechanism, a gantry system, a hydraulic system, and an electrical model constructed by three-dimensional drawing software.

5. The method for constructing a forklift digital twin based on a flight control system according to claim 1, characterized in that: The flight control system is a UAV flight control system; the flight control system includes a gyroscope, an accelerometer and a GPS, the gyroscope is used to detect the tilt angle of the forklift body, the accelerometer is used to obtain the body speed and body impact acceleration, and the GPS is used to locate the forklift position.

6. The method for constructing a forklift digital twin based on a flight control system according to claim 1, characterized in that: The multiple sensors include a lifting cylinder displacement sensor, a tilt cylinder displacement sensor and a weight sensor; the lifting cylinder displacement sensor and the tilt cylinder displacement sensor are used to detect the extension distance of the lifting cylinder and the tilt cylinder respectively; the weight sensor is used to detect the weight of the heavy object on the fork frame.

7. The method for constructing a forklift digital twin based on a flight control system according to claim 1, characterized in that: The display screen of the onboard computer dynamically displays the real-time three-dimensional posture and operation data of the forklift.

8. A forklift digital twin construction method based on a flight control system according to claim 1 or 5, characterized in that: The flight control system is any one of an APM flight control system, a PX4 flight control system or a PIX flight control system.

9. The method for constructing a forklift digital twin based on a flight control system according to claim 1, characterized in that: The ground station is an open source ground station that matches the flight control system, and is one of the mission planner ground station and the QGroundControl ground station.

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