Method of opening a wireless connection between a remote control device and a controller on a materials handling vehicle

Abstract

The present application relates to a method of opening a wireless connection between a remote control device and a controller on a materials handling vehicle. A system includes a remote control device usable by an operator interacting with a materials handling vehicle. The remote control device includes a wireless communication system including a wireless transmitter and a rechargeable power source. The system further includes a receiver at the vehicle for receiving transmissions from the wireless transmitter, a controller at the vehicle communicably coupled to the receiver, the controller responsive to receipt of a request from the remote control device, and a charging station at the vehicle for charging the rechargeable power source of the remote control device.

Description

[0001] This application is a divisional application of the invention patent application filed on December 18, 2019, with international filing date of 2019, national application number 201980089595.3, and entitled "Onboard Charging Station for Remote Control Equipment". Technical Field

[0002] This invention relates to an onboard charging station for remotely controlled devices, such as those that can be used by operators interacting with materials handling vehicles. Background Technology

[0003] Material handling vehicles are commonly used for picking goods in warehouses and distribution centers. These vehicles typically include a power unit and a load-carrying assembly, which may include load-carrying forks. The vehicles also have control structures for controlling their operation and movement.

[0004] In a typical picking operation, an operator fills out an order from available inventory items located in a storage area provided along one or more aisles along a warehouse or distribution center. The operator drives the vehicle between various picking locations for the items(s) to be picked. The operator may drive the vehicle either by using control structures on the vehicle or via a wireless remote control device associated with the vehicle (such as the remote control device disclosed in commonly owned U.S. Patent No. 9,082,293, the entire disclosure of which is incorporated herein by reference). Summary of the Invention

[0005] According to various aspects of the invention, a system includes a material handling vehicle and a remote control device usable by an operator interacting with the material handling vehicle. The remote control device includes a wireless communication system comprising a wireless transmitter and a rechargeable power supply. The system also includes a receiver at the vehicle for receiving transmissions from the wireless transmitter; a controller at the vehicle communicatively coupled to the receiver, the controller responding to receiving transmissions from the remote control device; and a charging station at the vehicle for charging the rechargeable power supply of the remote control device.

[0006] The rechargeable power source can be a supercapacitor.

[0007] The system may also include a pairing system for establishing communication between the remote control device and the vehicle.

[0008] Communication between remote control devices and vehicles can be established concurrently at charging stations during the charging of rechargeable power supplies.

[0009] Communication between the remote control device and the vehicle, as well as charging of the rechargeable power source at the charging station, can be initiated with a single action. This single action may include physically contacting a component of the remote control device with an element of the charging station.

[0010] The system may also include a pairing indicator that confirms the establishment of communication between the remote control device and the vehicle.

[0011] The time it takes to establish communication between remote control devices and vehicles can be less than or equal to the pairing time.

[0012] If no vehicle-related activity occurs within a first predetermined time interval after communication is established between the remote control device and the vehicle, then communication between the remote control device and the vehicle can be terminated and must be re-established using a pairing system. If no vehicle-related activity occurs within a second predetermined time interval after communication is established between the remote control device and the vehicle, and the second predetermined time interval is equal to or less than the first predetermined time interval, then communication between the remote control device and the vehicle can be terminated, but can be re-established without using a pairing system by performing an acknowledgment method using the remote control device. The acknowledgment method may include performing a button sequence on the remote control device.

[0013] A rechargeable power supply can be essentially fully charged by charging it at a charging station for five seconds or less, four seconds or less, or three seconds or less. This essentially fully charged state allows for at least two hours or at least eight hours of use for remotely controlled devices.

[0014] The charging station may include a guide structure to align the remote control device in the appropriate orientation for charging the rechargeable power source.

[0015] The system may also include an indicator at the vehicle location to indicate the charging status of the rechargeable power source. The indicator can show the charging status of the rechargeable power source when it is being charged at a charging station and during use of the remote control device. The indicator may include a series of lights, each representing the level of the rechargeable power source's charging status.

[0016] Remote control devices may include a fixation structure for securing the remote control device to one or more fingers of an operator's hand.

[0017] The remote control device may include at least one charging contact that engages at least one corresponding charging element on a charging station. The at least one charging contact may be recessed from an outer surface of the remote control device. At least one of the remote control device or the charging station may include a presence contact for detecting whether the at least one charging contact is properly engaged with the at least one corresponding charging element for charging a rechargeable power source, wherein if proper engagement is detected, power delivery to the rechargeable power source is enabled by the charging station, and if proper engagement is not detected, power delivery to the rechargeable power source is not enabled by the charging station. The arrangement of the remote control device and the charging station may be configured such that a presence contact indicates the removal of the remote control device from the charging station before the at least one charging contact disengages from the at least one corresponding charging element, thereby stopping power delivery from the charging station to the rechargeable power source before the at least one charging contact disengages from the at least one corresponding charging element.

[0018] The remote control device may include at least two charging contacts, which are positioned to engage corresponding charging elements on a charging station.

[0019] The charging station can be implemented in the vehicle's driving controls, and the rechargeable power source can be charged by the operator holding the driving controls.

[0020] If the sensed temperature is determined to be higher than a predetermined setpoint temperature, the rechargeable power supply can be discharged to a high-temperature charging state. The sensed temperature can be either the ambient temperature or the temperature of the rechargeable power supply.

[0021] If the sensed temperature is determined to be above a predetermined threshold temperature, the rechargeable power supply can be charged at the charging station to a predetermined charging level below 100% charge level.

[0022] Requests sent by a remote control device may include a driving request for the vehicle to move across the floor surface.

[0023] Charging stations can be located on the side of the vehicle or near the steering wheel.

[0024] When the rechargeable power supply of the remote control device is being charged at a charging station, the wireless communication system can enter a low-power mode.

[0025] When the operator is positioned on the vehicle, one or more components of the remote control device can be turned off or the power supplied to them can be reduced.

[0026] If the voltage of the rechargeable power source is below a voltage threshold before being charged by the charging station, the charging station can charge the rechargeable power source at a first power level. If the voltage of the rechargeable power source is above the voltage threshold before being charged by the charging station, the charging station can charge the rechargeable power source at a second power level. The first power level can be greater than the second power level. Regardless of whether the voltage of the rechargeable power source is above or below the voltage threshold before being charged by the charging station, the charging station can charge the rechargeable power source to a substantially fully charged state in approximately the same amount of time.

[0027] The remote control device may include at least one control communicatively coupled to a wireless communication system, wherein actuation of the control causes a wireless transmitter to wirelessly transmit a request to the vehicle.

[0028] According to other aspects of the invention, a kit is provided for retrofitting a material handling vehicle, the vehicle including a controller that responds to transmissions from an associated remote control device, the remote control device including a wireless communication system comprising a wireless transmitter and used by an operator interacting with the vehicle. The kit includes a charging station at the vehicle location configured to be electrically coupled to the vehicle's vehicle power supply for charging the rechargeable power supply of the remote control device.

[0029] The kit may also include a pairing system for establishing communication between the remote control device and the vehicle.

[0030] While the rechargeable power source is being charged at a charging station, communication between the remote control device and the vehicle can be established concurrently.

[0031] Communication between the remote control device and the vehicle, as well as charging of the rechargeable power source at the charging station, can be initiated with a single action. This single action may include physically contacting a component of the remote control device with elements of the charging station.

[0032] The kit may also include a pairing indicator, which confirms the establishment of communication between the remote control device and the vehicle.

[0033] The time it takes to establish communication between remote control devices and vehicles can be less than or equal to the pairing time.

[0034] A rechargeable power supply can be essentially fully charged by charging it at a charging station for five seconds or less, four seconds or less, or three seconds or less. This essentially fully charged state allows for at least two hours or at least eight hours of use for remotely controlled devices.

[0035] The charging station may include a guide structure to align the remote control device in the appropriate orientation for charging the rechargeable power source.

[0036] The kit may also include an indicator at the vehicle location to indicate the charging status of the rechargeable power source. The indicator can show the charging status of the rechargeable power source when charging at a charging station and during use of the remote control device. The indicator may include a series of lights, each representing the level of the rechargeable power source's charging status.

[0037] The remote control device may include at least one charging contact that engages at least one corresponding charging element on a charging station. At least one of the remote control device or the charging station may include a presence contact for detecting whether the at least one charging contact is properly engaged with the at least one corresponding charging element for charging a rechargeable power source, wherein if proper engagement is detected, the charging station enables power delivery to the rechargeable power source, and if proper engagement is not detected, the charging station does not enable power delivery to the rechargeable power source. The arrangement of the remote control device and the charging station may be configured such that a presence contact indicates the removal of the remote control device from the charging station before the at least one charging contact disengages from the at least one corresponding charging element, thereby stopping power delivery from the charging station to the rechargeable power source before the at least one charging contact disengages from the at least one corresponding charging element. The remote control device may include at least two charging contacts positioned to engage corresponding charging elements on the charging station.

[0038] The charging station can be implemented in the vehicle's driving controls, and the rechargeable power source can be charged by the operator holding the driving controls.

[0039] If the sensed temperature is determined to be above a predetermined threshold temperature, the rechargeable power supply can be charged at the charging station to a predetermined charge level below 100% of its rated capacity. The sensed temperature can be ambient temperature.

[0040] Charging stations can be located on the side of the vehicle.

[0041] According to another aspect of the invention, a method for charging a remotely controlled device is provided, the remotely controlled device including a wireless communication system comprising a wireless transmitter and a rechargeable power source. The method includes: initiating contact between a component of the remotely controlled device and an element of a charging station located at a vehicle; sensing the contact between the remotely controlled device component and the charging station element; supplying power from the charging station to the rechargeable power source after sensing the contact; interrupting the contact between the remotely controlled device component and the charging station element; sensing the interruption of the contact between the remotely controlled device component and the charging station element; and stopping the supply of power from the charging station to the rechargeable power source after sensing the interruption.

[0042] The rechargeable power source can be a supercapacitor.

[0043] The method may also include establishing communication between the remote control device and the vehicle when the remote control device component comes into contact with the charging station component.

[0044] While the rechargeable power source is being charged at a charging station, communication between the remote control device and the vehicle can be established concurrently.

[0045] Communication between the remote control device and the vehicle can occur during pairing, and charging the rechargeable power source to a substantially full charge at the charging station can occur during charging, wherein the pairing period and the charging period can overlap. The pairing period can be less than or equal to the charging period.

[0046] The method may also include using at least one of the auditory or visual queues to confirm the establishment of communication between the remote control device and the vehicle.

[0047] A rechargeable power supply can be essentially fully charged by charging it at a charging station for five seconds or less, four seconds or less, or three seconds or less.

[0048] A fully charged state of a rechargeable power source can provide at least two hours or at least eight hours of usage time for remotely controlled devices.

[0049] The method may also include displaying the charging status of the rechargeable power supply at the vehicle. The charging status of the rechargeable power supply can be displayed at the vehicle when it is being charged and during use of the remote control device. The charging status of the rechargeable power supply can be indicated by a series of lights, each light representing the level of the rechargeable power supply's charging status.

[0050] The contact between the component of the remote control device and the element of the charging station may include contact between at least one charging contact of the remote control device and at least one corresponding charging element on the charging station.

[0051] If no vehicle-related activity occurs within a first predetermined time interval after communication is established between the remote control device and the vehicle, then communication between the remote control device and the vehicle can be terminated and must be re-established using a pairing system. If no vehicle-related activity occurs within a second predetermined time interval after communication is established between the remote control device and the vehicle, and the second predetermined time interval is equal to or less than the first predetermined time interval, then communication between the remote control device and the vehicle can be terminated, but can be re-established by performing an acknowledgment method using the remote control device. The acknowledgment method may include performing a sequence of buttons on the remote control device.

[0052] The charging station can be implemented within the vehicle's driving controls, and the rechargeable power source can be charged by the operator holding the driving controls.

[0053] The method may further include discharging the rechargeable power supply to a high-temperature charging state if the sensed temperature is determined to be higher than a predetermined setpoint temperature. The sensed temperature may be the ambient temperature or the temperature of the rechargeable power supply.

[0054] If the sensed temperature is determined to be above a predetermined threshold temperature, the rechargeable power supply can be charged at a charging station to a predetermined charging level below 100% charge level.

[0055] Charging stations can be located on the side of the vehicle. Attached Figure Description

[0056] Figure 1 and Figure 2 These are side and top views of a material handling vehicle capable of remote wireless operation according to various aspects of the present invention.

[0057] Figure 2A This is a side view of another material handling vehicle capable of remote wireless operation according to various aspects of the present invention;

[0058] Figure 3 This is a schematic diagram of several components of a material handling vehicle capable of remote wireless operation according to various aspects of the present invention;

[0059] Figures 4-7 This is a view of a remote control device according to various aspects of the present invention;

[0060] Figure 8A and Figure 8B This is a cross-sectional view showing a remote control device integrated with a charging station according to various aspects of the present invention;

[0061] Figure 9 and Figure 10 This is a view of another remote control device according to various aspects of the present invention;

[0062] Figure 11 This is a schematic diagram of several components of a charging station according to various aspects of the present invention;

[0063] Figures 12-14 This is a view illustrating a remote control device and a charging station according to various aspects of the present invention;

[0064] Figure 15 This is a schematic diagram of several components of a remote control device according to various aspects of the present invention;

[0065] Figure 16 Methods according to various aspects of the present invention are described;

[0066] Figure 17 Pairing methods according to various aspects of the present invention are described;

[0067] Figure 18 Another pairing method according to various aspects of the present invention is described;

[0068] Figure 19 A method for re-pairing a vehicle and a remote control device according to various aspects of the present invention is described;

[0069] Figure 20 A method for re-establishing communication between a vehicle and a remote control device is described according to various aspects of the present invention;

[0070] Figure 21 A method for charging a remote control device according to various aspects of the present invention is described;

[0071] Figure 22 Another method for charging a remote control device according to various aspects of the present invention is described;

[0072] Figure 23 This is a schematic diagram of several components of a kit according to various aspects of the present invention;

[0073] Figure 24 This is a view of another remote control device according to various aspects of the present invention; and

[0074] Figure 25 This is a schematic diagram illustrating various aspects of the present invention. Detailed Implementation

[0075] In the following detailed description of the illustrated embodiments, reference is made to the accompanying drawings, which form a part of the description, in which specific embodiments in which the invention may be practiced are shown by way of illustration rather than limitation. It should be understood that other embodiments may be utilized and changes may be made without departing from the spirit and scope of the various embodiments of the invention.

[0076] Low-position picking truck

[0077] Now refer to the attached diagram, especially Figure 1 and Figure 2The material handling vehicle 10, illustrated as a low-level order picking truck, includes a load handling assembly 12 extending from a power unit 14. The vehicle 10 forms part of a system 8 according to various aspects of the invention, which will be described more fully below. The load handling assembly 12 includes a pair of forks 16, each fork 16 having a load support wheel assembly 18. In addition to or in lieu of the illustrated arrangement of the forks 16, the load handling assembly 12 may include other load handling features, such as load backrests, scissor lift forks, extended supports, or individual height-adjustable forks, to name just a few. Furthermore, the load handling assembly 12 may include load handling features such as masts, load platforms, collection cages, or other support structures carried by or otherwise provided by the forks 16 for handling loads supported and carried by the vehicle 10. Although this disclosure is made with reference to the illustrated vehicle 10, it will be apparent to those skilled in the art that vehicle 10 may include a variety of other industrial vehicles, such as forklifts, reach trucks, etc., and unless otherwise stated, the following description of the invention with reference to the accompanying drawings should not be limited to picking trucks. Furthermore, vehicle 10 may be implemented in other forms, styles, and features, including vehicles 10 excluding load-carrying components, such as trailers.

[0078] The power unit 14 shown includes a stepping operator station 20 that separates a first end section (opposite to the fork 16) of the power unit 14 from a second end section (proximity to the fork 16). The operator station 20 includes a platform 21 on which an operator can stand to drive the vehicle 10 and / or provides a position where the operator can operate various included features of the vehicle 10.

[0079] Presence sensor 22 can be provided (see Figure 2 This is to detect the presence of an operator on vehicle 10. For example, presence sensor 22 may be located on, above, or below platform 21, or otherwise provided around operator station 20. Figure 2 In the exemplary vehicle 10, presence sensors 22 are shown in dashed lines, indicating that they are located below platform 21. In this arrangement, presence sensors 22 may include load sensors, switches, etc. Alternatively, presence sensors 22 may be implemented above platform 21, such as by using ultrasonic, capacitive, or other suitable sensing techniques. The use of presence sensors 22 will be described in more detail herein.

[0080] according to Figure 2 In one embodiment shown, vehicle 10 may include a pole extending vertically from power unit 14 and including antenna 30 for receiving control signals from a corresponding wireless remote control device 32. The pole may include a top light 33, such as... Figure 1 and Figure 2 As shown. According to Figure 2A In another embodiment shown, the antenna may be located within other vehicle components, allowing control signals from the remote control device 32 to be received elsewhere in the vehicle 10, as will be discussed below. The remote control device 32 includes additional components of system 8, which will be described in more detail below.

[0081] The remote control device 32 can be manually operated by an operator, for example, by pressing a button or other control, to cause the remote control device 32 to transmit a first-type signal specifying a driving request to at least the vehicle 10 paired with the remote control device 32. A driving request is a command requesting the vehicle 10 to drive, as will be described in more detail herein. While the remote control device 32... Figure 1 and Figure 2The structure is shown as a finger mounting structure, but it can be implemented in various ways to remotely control the device 32, including, for example, a glove structure, a lanyard or belt mounting structure. Furthermore, the vehicle 10 and the remote control device 32 may include any additional and / or alternative features or implementations, examples of which are disclosed in U.S. Provisional Patent Application Serial No. 60 / 825,688, filed September 14, 2006, entitled “SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE”; U.S. Patent Application Serial No. 11 / 855,310, filed September 14, 2007, entitled “SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE”, now U.S. Patent No. 9,082,293; and U.S. Patent Application Serial No. 11 / 855,310, filed September 14, 2007, entitled “SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE”; and U.S. Patent Application Serial No. 9,082,293, filed September 14, 2007, entitled “SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE”. The following are listed as patent applications: U.S. Patent Application Serial No. 11 / 855,324 entitled “VEHICLE”, now U.S. Patent No. 8,072,309; U.S. Provisional Patent Application Serial No. 61 / 222,632 entitled “APPARATUS FOR REMOTELY CONTROLLING AMATERIALS HANDLING VEHICLE”, filed July 2, 2009; U.S. Patent Application Serial No. 12 / 631,007 entitled “MULTIPLE ZONE SENSING FOR MATERIALSHANDLING VEHICLES”, filed December 4, 2009, now U.S. Patent No. 9,645,968; and U.S. Patent Application Serial No. 12 / 631,007 entitled “MULTIPLE ZONE SENSING FOR REMOTELY CONTROLLED MATERIALS HANDLING”, filed December 4, 2008. The disclosures in U.S. Provisional Patent Application Serial No. 61 / 119,952, entitled “VEHICLES”, and / or U.S. Patent No. 7,017,689, entitled “ELECTRICAL STEERING ASSIST FOR MATERIAL HANDLING VEHICLE”, issued March 28, 2006, are incorporated herein by reference in their entirety. Additional details relating to the remote control device 32 will be discussed in detail below.

[0082] Vehicle 10 also includes one or more non-contact obstacle sensors 40, which are provided around vehicle 10, for example toward the first end section of power unit 14, such as Figure 1 and Figure 2 As shown in the diagram. The obstacle sensor 40 is operable to define at least one detection zone. For example, when the vehicle 10 moves in response to a driving request received wirelessly from the remote control device 32, the at least one detection zone may define an area at least partially in front of the vehicle 10 in the forward direction of travel, as also described in more detail herein.

[0083] Obstacle sensor 40 may include any suitable proximity detection technology, such as ultrasonic sensors, image capture devices, infrared sensors, laser scanner sensors, etc., capable of detecting the presence of an object / obstacle or generating a signal that can be analyzed to detect the presence of an object / obstacle within a predefined detection area(s). Figure 1 and Figure 2 In the exemplary embodiment shown, the vehicle 10 includes a first obstacle detector 42 mounted to the power unit 14 and a pair of second obstacle detectors 44A and 44B. The first obstacle detector 42 is located along the vertical axis V of the vehicle 10, which defines the vertical direction. A The second obstacle detectors 44A and 44B are spaced apart from the first obstacle detector 42, meaning they are located below (closer to the ground than the first obstacle detector 42). See [reference needed]. Figure 1 The second obstacle detectors 44A and 44B are along the horizontal axis H of the vehicle 10, which is defined in the horizontal direction. A Separated from each other, see Figure 2 .

[0084] The first obstacle detector 42 may include a sweeping laser sensor capable of detecting objects, for example, in the first, second, and third regions Z1, Z2, Z3 (also referred to herein as scanning regions or detection regions), which may include planar regions, see [link to relevant documentation]. Figure 1 and Figure 2The second zone Z2 may include a “stop zone,” and the first and third zones Z1 and Z3 may include left and right “steering bumper zones,” such as the stop zone and left and right steering bumper zones described in U.S. Patent No. 8,452,464, issued May 28, 2013, entitled “STEER CORRECTION FOR AREMOTELY OPERATED MATERIALS HANDLING VEHICLE,” the entire disclosure of which is incorporated herein by reference. It should be noted that the first obstacle detector 42 may be able to detect objects in more or fewer zones than the three zones Z1, Z2, Z3 shown. In an exemplary detection zone configuration, any or all detection zones may be used, as disclosed in U.S. Patent No. 9,002,581, issued April 7, 2015, entitled “OBJECTTRACKING AND STEER MANEUVERS FOR MATERIALS HANDLING VEHICLES,” the entire disclosure of which is incorporated herein by reference.

[0085] The second obstacle detectors 44A and 44B may include point laser sensors capable of detecting the area between one or more zones Z1, Z2, Z3 of the first obstacle detector 42 and the vehicle 10 (i.e., below one or more of zones Z1, Z2, Z3, such as...). Figure 1 As shown in the diagram) and / or objects passing through zones Z1, Z2, and Z3, and preferably objects below at least zone Z2. Therefore, the second obstacle detectors 44A and 44B are capable of detecting objects located in the non-detection zone DZ of the first obstacle detector 42, see [reference]. Figure 1 That is, the non-detection zone DZ is defined as the area below zones Z1, Z2, and Z3 and is therefore not detected by the first obstacle detector 42. Therefore, the first obstacle detector 42 is used to detect objects located outside the non-detection zone DZ along the travel path of the power unit 14, while the second obstacle detectors 44A and 44B are used to sense objects along the travel path of the power unit 14 located in the non-detection zone DZ directly in front of the vehicle 10, such as... Figure 1 As shown in the image.

[0086] Additional sensor configurations and / or detection areas may be used, as discussed in the various patents and patent applications incorporated herein by reference.

[0087] Figure 1 and Figure 2 The vehicle 10 shown also includes a charging station 50, which includes additional components of the system 8 and is provided for charging the rechargeable power source of the remote control device 32. Additional details related to the charging station 50 will be described below.

[0088] Control system for remote operation of low-position picking trucks

[0089] refer to Figure 3 The block diagram illustrates a control arrangement for integrating remote control commands with vehicle 10. A receiver 102, such as a Bluetooth Low Energy (BLE) radio transceiver, is provided for receiving commands issued by remote control device 32. The receiver 102 transmits the received control signals to controller 103, which responds appropriately to the received commands and is therefore also referred to herein as the main controller. In this respect, controller 103 is implemented in hardware and may also execute software (including firmware, resident software, microcode, etc.). Furthermore, aspects of the invention can take the form of a computer program product embodied in one or more computer-readable media having computer-readable program code implemented thereon. For example, vehicle 10 may include a memory storing the computer program product, which, when implemented by a processor of controller 103, implements steering correction as described more fully herein.

[0090] Therefore, controller 103 may at least partially define a data processing system suitable for storing and / or executing program code and may include at least one processor, for example, directly or indirectly coupled to memory elements via a system bus or other suitable connection. Memory elements may include local memory used during the actual execution of the program code, memory integrated into a microcontroller or application-specific integrated circuit (ASIC), programmable gate arrays or other reconfigurable processing devices, etc.

[0091] The response of the controller 103 to commands received wirelessly (e.g., via a wireless transmitter 178 of the remote control device 32, which will be discussed below) and transmitted to the receiver 102 on the vehicle 10 may include one or more actions or no actions, depending on the logic being implemented. Active actions may include controlling, adjusting, or otherwise influencing one or more components of the vehicle 10. The controller 103 may also receive information from other inputs 104 (e.g., from sources such as presence sensor 22, obstacle sensor 40, switches, load sensors, encoders, and other devices / features available on the vehicle 10) to determine appropriate actions in response to commands received from the remote control device 32. Sensors 22, 40, etc., may be connected to the controller 103 via input 104 or via a suitable truck network (such as a Control Area Network (CAN) bus 110).

[0092] In an exemplary arrangement, the remote control device 32 is operable to wirelessly transmit control signals to a receiver 102 on the vehicle 10, the control signals representing a first-type signal such as a driving command. A driving command is also referred to herein as a “driving signal,” “driving request,” or “forward signal.” A driving request is used to initiate a request to drive the vehicle 10, for example, by the vehicle 10 moving forward or jogging for a predetermined distance or time in a first direction, provided the driving signal is received by the receiver 102 and / or transmitted by the remote control device 32. For example, the first direction can be defined by the direction in which the vehicle 10 first moves in the power unit 14, i.e., the direction in which the fork 16 is backward. However, other driving directions can be defined alternatively. Furthermore, the vehicle 10 can be controlled to travel in a generally straight direction or along a previously determined heading. Accordingly, the limited driving distance can be specified by an approximate driving distance, driving time, or other measurement.

[0093] Therefore, the first type of signal received by receiver 102 is transmitted to controller 103. If controller 103 determines that the driving signal is a valid driving signal and the current vehicle condition is appropriate (explained in more detail in U.S. Patent No. 9,082,293, which is incorporated herein by reference), then controller 103 sends a signal to the appropriate control configuration of vehicle 10 to proceed and then stop vehicle 10. Stopping vehicle 10 can be achieved, for example, by allowing vehicle 10 to coast to a stop or by initiating a braking operation to bring vehicle 10 to a stop.

[0094] As an example, controller 103 may be communicatively coupled to a traction control system, shown as a traction motor controller 106 of vehicle 10. Traction motor controller 106 is coupled to a traction motor 107 that drives at least one steering wheel 108 of vehicle 10. Controller 103 may communicate with traction motor controller 106 in response to receiving a driving request from remote control device 32 to accelerate, decelerate, adjust, and / or otherwise limit the speed of vehicle 10. Controller 103 may also be communicatively coupled to steering controller 112, which is coupled to steering motor 114 that steers at least one steering wheel 108 of vehicle 10. At this point, in response to receiving a driving request from remote control device 32, vehicle 10 may be controlled by controller 103 to travel a desired path or maintain a desired heading.

[0095] As another illustrative example, controller 103 may be communicatively coupled to brake controller 116, which controls vehicle brakes 117 to decelerate, stop, or otherwise control the speed of vehicle 10 in response to receiving a driving request from remote control device 32. Furthermore, where applicable, controller 103 may be communicatively coupled to other vehicle features (such as main contactor 118 and / or other outputs 119 associated with vehicle 10) to perform desired actions in response to enabling remote driving functionality.

[0096] According to various aspects of the invention, the controller 103 can communicate with the receiver 102 and the traction motor controller 106 to operate the vehicle 10 under remote control in response to receiving a driving command from the associated remote control device 32. Furthermore, if the vehicle 10 is driven under remote control in response to a driving request and detects an obstacle in one or more of the detection zones Z1, Z2, Z3, then the controller 103 can be configured to perform various actions. In this regard, when the controller 103 receives a driving signal from the remote control device 32, the controller 103 can consider any number of factors to determine whether action should be taken in response to the received driving signal to initiate and / or maintain the movement of the vehicle 10.

[0097] Accordingly, if vehicle 10 moves in response to a command received from remote control device 32, then controller 103 can dynamically change, control, adjust, or otherwise influence the remote control operation, such as by stopping vehicle 10, changing the steering angle of vehicle 10, or taking other actions. Therefore, specific vehicle characteristics, the state / condition of one or more vehicle characteristics, the vehicle environment, etc., can affect how controller 103 responds to driving requests from remote control device 32.

[0098] Controller 103 may reject a received driving request based on predetermined conditions, such as those related to the environment or one or more operational factors. For example, controller 103 may ignore other valid driving requests based on information obtained from one or more of sensors 22, 40. As an illustration, according to various aspects of the invention, when determining whether to respond to a driving command from remote control device 32, controller 103 may optionally consider factors such as whether an operator is on vehicle 10. As mentioned above, vehicle 10 may include at least one presence sensor 22 for detecting whether an operator is on vehicle 10. In this respect, controller 103 may also be configured to respond to a driving request to operate vehicle 10 under remote control when presence sensor 22 indicates that no operator is on vehicle 10. Therefore, in this embodiment, vehicle 10 cannot be operated in response to a wireless command from remote control device 32 unless the operator physically leaves vehicle 10. Similarly, if obstacle sensor 40 detects an object, including an operator, approaching and / or nearing vehicle 10, then controller 103 may reject a driving request from remote control device 32. Therefore, in the exemplary embodiment, the operator must be located within a limited area of ​​vehicle 10, for example, close enough to be within wireless communication range (this can be limited by setting a maximum distance between the operator and vehicle 10). Other arrangements may be implemented alternatively.

[0099] Any other number of reasonable conditions, factors, parameters or other considerations may also / alternatively be implemented by controller 103 to interpret and take action in response to signals received from transmitter 178. Other exemplary factors include U.S. Provisional Patent Application Serial No. 60 / 825,688 entitled "SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE"; U.S. Patent Application Serial No. 11 / 855,310 entitled "SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE", now U.S. Patent No. 9,082,293; U.S. Patent Application Serial No. 11 / 855,324 entitled "SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE", now U.S. Patent No. 8,072,309; and U.S. Patent Application Serial No. 11 / 855,324 entitled "SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE", now U.S. Patent No. 8,072,309; and U.S. Patent Application Serial No. APPARATUS FOR REMOTELY CONTROLLING A MATERIALS The disclosures of the following U.S. Provisional Patent Application No. 61 / 222,632 entitled “HANDLING VEHICLE”; U.S. Patent Application No. 12 / 631,007 entitled “MULTIPLE ZONE SENSING FOR MATERIALS HANDLING VEHICLES”, now U.S. Patent No. 9,645,968; and U.S. Provisional Patent Application No. 61 / 119,952 entitled “MULTIPLE ZONE SENSING FOR REMOTELY CONTROLLED MATERIALSHANDLING VEHICLES” are described in more detail herein, and are incorporated herein by reference.

[0100] Upon confirmation of a driving request, controller 103 interacts with traction motor controller 106, for example, directly or indirectly (e.g., via a bus such as CAN bus 110, if used), to propel vehicle 10. Depending on the specific implementation, controller 103 may interact with traction motor controller 106 and optionally steering controller 112 to propel vehicle 10 whenever a driving control signal is received. Alternatively, controller 103 may interact with traction motor controller 106 and optionally steering controller 112 to advance vehicle 10 for a period of time or a predetermined distance in response to the detection and maintenance of driving control on remote control device 32. Furthermore, controller 103 may be configured to “time out” and stop driving vehicle 10 based on a predetermined event (such as exceeding a predetermined time period or driving distance), regardless of the detection of maintenance of the corresponding control on remote control device 32.

[0101] The remote control device 32 may also be operable to transmit a second type of signal (such as a "stop signal," indicating that vehicle 10 should brake and / or otherwise come to a stop). The second type of signal may also be implicit, for example, after a "drive" command has been executed, such as after vehicle 10 has traveled a predetermined distance, a predetermined time, etc., under remote control in response to the drive command. If controller 103 determines that the wirelessly received signal is a stop signal, then controller 103 sends a signal to the traction motor controller 106, brake controller 116, and / or other truck components to bring vehicle 10 to a stop. Alternatively to the stop signal, the second type of signal may include a "coasting signal" or a "controlled deceleration signal" indicating that vehicle 10 should coast and eventually decelerate to a stop.

[0102] The time required for vehicle 10 to come to a complete stop can vary depending on factors such as the intended application, environmental conditions, the capabilities of the specific vehicle 10, the load on vehicle 10, and other similar factors. For example, after a proper jogging movement, it may be desirable to allow vehicle 10 to "glide" a certain distance before coming to a complete stop, allowing vehicle 10 to stop slowly. This can be achieved by using regenerative braking to decelerate vehicle 10 to a stop. Alternatively, braking can be applied after a predetermined delay time to allow vehicle 10 to travel an additional predetermined distance after the stopping operation is initiated. For example, if an object is detected in the path of vehicle 10 or if an immediate stop is desired after a successful jogging operation, it may also be desirable to stop vehicle 10 relatively quickly. For example, controller 103 may apply a predetermined torque to the braking operation. In this case, controller 103 may instruct brake controller 116 to apply brake 117 to stop vehicle 10.

[0103] Figure 3The diagram also shows an onboard charging station 50 that can communicate with controller 103. As will be explained in more detail below, charging station 50 can be used to charge the rechargeable power supply 180 of wireless remote control device 32. Charging station 50 can be located on the side of vehicle 10, for example near operator station 20, near manual driving controls of vehicle 10 (such as...). Figure 1 and Figure 2 (as shown in the image), or located on the side panel of the power unit 14.

[0104] Pairing system 34 can wirelessly communicate with a compatible short-range system on wireless remote control device 32 using a short-range system. Using pairing system 34, vehicle 10 and wireless remote control device 32 can be "paired," such that vehicle 10 will transmit and receive messages only from its paired wireless remote control device 32. In addition to or instead of short-range or other types of wireless communication (such as Near Field Communication (NFC)), pairing system 34 can also use physical contacts that allow electrical communication between remote control device 32 and vehicle 10, at least for the initial pairing procedure. For example, electrical contacts of charging station 50 for charging remote control device 32 can be used to pair vehicle 10 with remote control device 32, as will be described in more detail herein. Pairing system 34 includes components that physically implement communication methods (e.g., Bluetooth, NFC, BLE, Wi-Fi, etc.) for sending messages, and includes components that programmatically exchange information according to an agreed protocol to establish and maintain pairing. Therefore, pairing system 34 includes devices capable of executing programmable instructions to implement predetermined algorithms and protocols to complete the pairing operation.

[0105] exist Figure 3 In this design, the charging station 50, receiver 102, and pairing system 34 are depicted as distinct functional blocks. However, those skilled in the art will recognize that two or more of these components can be combined into a single element to provide a multifunctional device.

[0106] system

[0107] As described above, according to one aspect of the present invention, the vehicle 10 (including the charging station 50) and the remote control device 32 form a system 8. The remote control device 32 and the charging station 50 will now be described in sequence.

[0108] refer to Figure 4 - Figure 8 shows that the remote control device 32 according to this embodiment is a finger-mounted device, but the remote control device 32 can take other forms, such as a glove-mounted device, a wrist-worn device, a lanyard-mounted device, etc. The remote control device 32 can be mounted on one, two, or more than two fingers of the operator.

[0109] Figure 4- The remote control device 32 shown in Figure 8 includes a polymer rigid base 172 (see Figure 8). Figure 6 The base 172 and the upper housing 174 are coupled together by any suitable means and define the internal components for receiving the remote control device 32 (including the wireless transmitter 178 (as referenced above)). Figure 3 The wireless transmitter 178 described includes a wireless communication system 456 and an internal region 176 of a rechargeable power supply 180. In one exemplary embodiment, the wireless transmitter 178 includes a model BGM121 manufactured by SiLabs. It should be noted that the terms "transmitter" and "receiver" as used herein are intended to refer to devices capable of unidirectional communication, i.e., that the device only transmits or receives signals, or devices capable of bidirectional communication, such as transceivers that both transmit and receive signals.

[0110] The rechargeable power supply 180 can be a supercapacitor, a high-capacity battery, etc. For example, an AVX supercapacitor, model SCCR20E335PRB, with a rated voltage of 3V and a capacitance of 3.3F, can be used. The rechargeable power supply 180 is small enough to fit within the internal area 176, while also having sufficient capacity when substantially fully charged to provide a usage period of at least two hours, at least four hours, at least eight hours, or more for the remote control device 32. A usage period of up to eight hours is preferred to correspond to an operator's eight-hour work shift.

[0111] A supercapacitor (also known as a supercapacitor or ultracapacitor) is a high-capacitance capacitor with a capacitance value far exceeding that of other capacitors, but typically has a lower voltage limit to bridge the gap between electrolytic capacitors and rechargeable batteries. They typically store 10 to 100 times more energy per unit volume or mass than electrolytic capacitors, can accept and deliver charge faster than batteries, and can withstand more charge and discharge cycles than rechargeable batteries. Because supercapacitors can be used in applications requiring many fast charge / discharge cycles, some embodiments of the remote control device 32 may include a supercapacitor as a rechargeable power source 180. In embodiments of the invention, the current supplied to the supercapacitor may be limited to approximately 2 A and can be fully charged in approximately 2 seconds or less. Regardless of the specific type of rechargeable power source 180 used, embodiments of the invention anticipate recharging the rechargeable power source 180 to a desired amount (such as a fully charged state, or a state of charge below essentially full charge) via charging station 50 within the desired charging period (as will be discussed in detail herein). The power supplied by the charging station 50 to the rechargeable power source 180 can vary depending on the capacity of the rechargeable power source 180, the desired amount of charging, and / or the desired charging period, as will be discussed in more detail herein.

[0112] refer to Figure 6 The remote control device 32 also includes a fixing structure 188 for fixing the remote control device 32 to one or more fingers of the operator's hand. Figure 6 The fixing structure 188 in the illustrated embodiment includes a retaining strap 190, which includes, for example, a hook-and-loop fastener 191 to secure the retaining strap 190 to a single finger (e.g., the index finger) of the operator. The remote control device 32 is provided with first and second slots 192A and 192B located at opposite ends of the remote control device 32 for receiving the retaining strap 190.

[0113] Figure 6 The retaining band 190 shown defines a first finger receiving area 194 for receiving a single finger O of an operator using the remote control device 32. F (see Figure 1 and Figure 2Right-hand and left-hand versions of the remote control device 32 can be created. The remote control device 32 is releasably held on the operator's index finger via a retaining strap 190. In one exemplary embodiment, a first end 190A of the retaining strap 190 passes through a first slot 192A and a second end 190B of the retaining strap 190 passes through a second slot 192B. The first end 190A of the retaining strap 190 can be permanently fastened to a rigid base 172, for example, by stitching or gluing, while the second end 190B of the retaining strap 190 can be releasably inserted through the second slot 192B and folded back such that hook-and-loop fasteners 191 engage with each other to secure the retaining strap 190 to the operator's finger. The retaining strap 190 can be adjusted to accommodate different finger sizes or to allow the remote control device 32 to be worn over a glove (not shown). Note that other types of retaining straps 190 can be used.

[0114] The remote control device 32 also includes at least one control, in Figure 4 - Figure 8 shows controls 196A-C as the first, second, and third controls. Each control 196A-C includes a button 197A-C and a dual-state switch 198A-C located below the corresponding button 197A-C. Switches 198A-C are communicatively coupled to a wireless communication system 456, such that actuation of each of the controls 196A-C causes a wireless transmitter 178 to wirelessly transmit a corresponding request to the vehicle 10. Figure 4 - In the exemplary remote control device 32 depicted in Figure 8: a first control 196A includes a drive button 197A, which, when pressed, causes a wireless transmitter 178 to wirelessly transmit a request to drive the vehicle 10 across the floor surface; a second control 196B includes a horn button 197B, which, when pressed, causes a wireless transmitter 178 to wirelessly transmit a request to sound a horn / alarm from the vehicle 10; and a third control 196C includes a brake button 197C, which, when pressed, causes a wireless transmitter 178 to wirelessly transmit a request to stop the vehicle (if moving under wireless control) and optionally power off.

[0115] The remote control device 32 is compact, and essentially the entire device can be mounted and positioned directly above the operator's index finger. Therefore, the interference caused by wearing the remote control device 32 on the operator performing work tasks is minimal or non-existent. Because the rigid base 172 and upper housing 174 are preferably formed of a durable and rigid polymeric material (such as acrylonitrile butadiene styrene (ABS), polycarbonate, or nylon), the remote control device 32 is durable and long-lasting. The rigid base 172 and upper housing 174 define a durable, generally non-flexible, and rigid structure.

[0116] The operator can easily manually actuate the drive button 197A with his / her thumb to cause the wireless transmitter 178 to wirelessly transmit a first-type signal, specifying at least a driving request or command, to the vehicle 10. It is anticipated that as long as the operator holds down the drive button 197A, the driving request can cause the vehicle 10 to move, or to travel a predetermined distance or a predetermined amount of time. For example, the horn button 197B and the brake button 197C can be actuated by the operator's other hand.

[0117] like Figure 4 and Figure 5 As shown, the remote control device 32 also includes one or more charging contacts 210. It should be noted that more or fewer charging contacts 210 than the four shown can be used; for example, one charging contact 210 or two or more charging contacts 210 can be used. Furthermore, the remote control device 32 also includes one or more sensors in the form of a first present contact 212. Figure 4 and Figure 5 The diagram shows a single first presence contact 212 located between four charging contacts 210. The charging contacts 210 and the first presence contact 212 can be arranged within an opening 214 formed in the outer surface of the upper housing 174 of the remote control device 32. The tops of the charging contacts 210 and the first presence contact 212 can be positioned below the outer surface of the upper housing, i.e., the charging contacts 210 and the first presence contact 212 can be recessed into the opening 214, which prevents damage to the charging contacts 210 and the first presence contact 212 due to accidental contact. It should be noted that other configurations of the number, orientation, and placement of the charging contacts 210 and(one or more) first presence contacts 212 can be used without departing from the scope and spirit of the invention.

[0118] In embodiments, charging contact 210 mates with or engages with components (e.g., electrical contacts of on-board charging station 50 or charging element 220 (discussed below)), and complementary second sensors (such as switches, spring pins, or pressure pins of on-board charging station 50) in the form of first present contact 212 and second present contact 222 are used. Figure 8A and Figure 8B As shown in the diagram, and described in more detail herein, they may be engaged or mated. It should be noted that one or more of the charging contacts 210 and the corresponding charging elements 220 may be provided for redundancy. In one example, Figures 4-7 The four charging contacts 210 shown are Figures 12-14 The four charging elements 220 shown can be configured as two pairs of redundant contacts / elements 210 / 220, wherein charging of the rechargeable power supply 180 (discussed below) is enabled as long as one charging contact 210 from each pair engages with and electrically communicates with its corresponding charging element 220.

[0119] Embodiments of the invention also contemplate contactless or inductive charging, wherein the rechargeable power supply 180 of the remote control device 32 can be charged by proximity to a compatible inductive charging station (not shown) or by the remote control device 32 located on its surface. Such an inductive charging station may be located, for example, in the driving or steering controls of the vehicle 10, such that the rechargeable power supply 180 can be charged while the operator manually drives the vehicle 10 from the operator station 20.

[0120] Figure 9 and Figure 10 Another exemplary remote control device 32 is illustrated, wherein the same reference numerals are used as those above for... Figure 4 - The components listed in Figure 8 correspond to similar components. The remote control device 32 according to this embodiment is designed as a two-finger design, i.e. Figure 9 and Figure 10 The fixing structure 188 in the illustrated embodiment includes a retaining strap 190 that defines first and second finger receiving areas 194, 195 for receiving the index and middle fingers of an operator using the remote control device 32. Figure 9 and Figure 10 The remote control device 32 includes two charging contacts 210, instead of Figure 4 - The four charging contacts 210 in the remote control device 32 of Figure 8. Figure 9 and Figure 10 The remaining components of the remote control device 32 can generally be connected with Figure 4 The remote control device 32 in Figure 8 is largely the same, so it will not be described in detail in this article.

[0121] Figure 11A functional block diagram of a vehicle charging station 50 according to the principles of the present invention is provided, wherein a pairing system 34 is incorporated into the charging station 50. As explained in more detail below, the charging station 50 may include a receiver 102, such as a Bluetooth Low Energy (BLE) radio transceiver 402 capable of communicating with the vehicle's controller 103. Although not shown, communication may be made via the vehicle's CAN bus, therefore the charging station 50 may include a CAN bus interface. The charging station 50 may also include one or more light-emitting diodes (LEDs) 404 or other visual indicators to help convey information to the operator. For example, one LED may be used to indicate that the remote control device 32 is currently coupled to the charging station 50. Other LEDs may indicate the current charging status of the rechargeable power supply 180 of the remote control device. A current limiter 406 or other protective circuitry may be provided to help ensure that the remote control device 32 is safely recharged, as the current limiter 406 allows voltage from the vehicle's power supply to be supplied to the charging element 220 of the charging station 50 for charging the rechargeable power supply 180 of the remote control device. These charging elements 220 interface with the charging contacts 210 of the remote control device 32 and provide an electrical connection between the vehicle's power supply and the rechargeable power source 180 of the remote control device 32. A second presence contact 222 engages with the first presence contact 212 to detect when the remote control device 32 is physically connected to the charging station 50, causing the charging contact 210 to engage with the charging element 220. According to an embodiment, a pairing process is initiated after the second presence contact 222 is engaged by the first presence contact 212.

[0122] It should be noted that the first and second presence contacts 212 and 222 can be provided on either the remote control device 32 or the charging station 50, respectively. That is, although the second presence contact 222 is illustrated on the charging station 50 and the first presence contact 212 is illustrated on the remote control device 32, the second presence contact 222 can be located on the remote control device 32 and the first presence contact 212 can be located on the charging station 50.

[0123] The relationship between the second present contact 222 and the charging element 220 is such that when a charging process is initiated, the charging contact 210 of the remote control device 32 and the charging element 220 of the charging station 50 are in contact with each other before the second present contact 222 engages with the first present contact 212. (See also...) Figure 8AThis shows that the height of the second presence contact 222 is less than the height of the charging element 220, and the height is measured relative to the top surfaces of the element housing 220A and the second presence contact housing 222A from which the corresponding charging element 220 and second presence contact 222 extend. Power supply to the remote control device 32 via the charging element / charging contact 220 / 210 is initiated only after the second presence contact 222 engages the first presence contact 212. During the charging process, the charging contact 210 of the remote control device 32 engages with the charging element 220 of the charging station 50, and the second presence contact 222 engages with the first presence contact 212, thereby enabling power supply to the remote control device 32 from the charging station 50 via the charging element / charging contact 220 / 210. See [link to documentation]. Figure 8B After the rechargeable power supply 180 is charged to a desired amount, such as fully charged or charged to a lower desired amount than fully charged as described herein, power supply from the charging station 50 to the remote control device 32 via the charging element / charging contact 220 / 210 is cut off. If the remote control device 32 is removed from the charging station 50 before the rechargeable power supply 180 is charged to the desired amount, as the remote control device 32 is removed from the charging station 50, the second presence contact 222 disengages from the first presence contact 212 before the charging element 220 disengages from the charging contact 210. When the second presence contact 222 disengages from the first presence contact 212, the power supply from the charging station 50 to the remote control device 32 via the charging element / charging contact 220 / 210 is cut off. This arrangement is designed to prevent arcing between the charging element 220 and the charging contact 210. The use of a spring-loaded first presence contact 212 and a second presence contact 222 provides the following advantages: precise control over the relative height of the second presence contact 222 and the charging element 220; a small footprint; good sealing, for example, to prevent moisture from entering the second presence contact housing 222A from around the second presence contact 222; and it allows the first presence contact 212 to be distinguished from foreign objects (such as a piece of metal), which prevents current from flowing into such foreign objects if it is placed in contact with one or more of the second presence contact 222 and the charging element 220.

[0124] As an alternative to the presence of contacts 212, 222 for initiating power supply from charging station 50 to remote control device 32, a separate switch may be present, which the operator engages to begin the charging operation. In one specific embodiment using inductive charging, such a switch may be integrated into the vehicle's steering controls, allowing detection of the operator's grip on the steering controls and subsequent activation of charging.

[0125] The control 414 used to provide control signals to operate the LED 404 can come from various sources. For example, when the remote control device 32 is operating within the range of the charging station 50, the controller 103 can receive information about the charging status of the rechargeable power supply 180 and drive the display of the LED 404 to convey this information using the CAN bus interface. When the remote control device 32 is coupled to the charging station 50, the LED 404 can be used to convey a) that the remote control device 32 is physically connected to the charging station 50, b) that there is a remote control device 32 currently paired with the vehicle's controller 103, c) the progress / charging status of the current charging operation, and / or d) the charging status of the rechargeable power supply 180. Information for items c) and d) can be sent by the remote control device 32 to the charging station 50, for example, via a Bluetooth Low Energy (BLE) connection, which will be discussed in more detail below. According to one aspect, because the pairing and charging process is performed very quickly, the LED 404 may not display the progress / charging status of the current charging operation. After the remote control device 32 is removed from the charging station 50, the remote control device 32 can store its charging profile and then send the charging profile to the charging station 50, for example, via a BLE connection. The charging profile can be evaluated, for example, by the controller 103 to determine whether proper charging of the rechargeable power supply 180 has occurred. The second presence contact 222 can also send a control signal to the control 414, indicating whether the charging contact 210 of the remote control device 32 is properly coupled to the corresponding charging element 220 of the charging station 50.

[0126] Figures 12-14 Other features of the charging station 50 located at vehicle 10 are illustrated. The charging station 50 may include one or more physical protrusions or guide structures 420 that help guide the remote control device 32 to proper alignment, such that the charging element 220 of the station aligns with the charging contacts 210 of the remote control device 32; that is, the guide structures 420(one or more) align the remote control device 32 in the correct orientation for charging the rechargeable power source 180. Figure 12 The diagram shows a single guide structure 420 comprising multiple guide surfaces. One or more guide structures 420 may be positioned around the charging element 220 and may be shaped or tilted such that the remote control device 32 is physically guided to be properly aligned when the operator places the remote control device 32 in the charging station.

[0127] exist Figure 13In this embodiment, LED 404 includes a visual indicator 424 that indicates that the remote control device 32 is attached to the charging station 50. The visual indicator 424 can illuminate, flash, or gradually fill with a first color to indicate that the remote control device 32 is attached to the charging station 50, and fill with a second color or fully fill with the first color to indicate that the remote control device 32 has been paired with the vehicle controller 103. That is, the visual indicator 424 can use the second color or fully fill with the first color as a pairing indicator to confirm the establishment of communication between the remote control device 32 and the vehicle 10. Furthermore, according to an optional aspect of the invention, after communication is established between the remote control device 32 and the vehicle 10, LED 404 can flash, illuminate with a second color, or provide some other visual indication as a clue for the operator to perform an action, or as a test to confirm that the remote control device 32 is functioning and can communicate with the vehicle 10, such as by concurrently pressing the horn button 197B and the brake button 197C. It should be understood that, unlike a single indicator that can serve both functions, a separate indicator can be used to indicate that the remote control device 32 is attached to the charging station 50 and that the remote control device 32 has been paired with the vehicle 10.

[0128] LED 404 can also be used as an indicator to identify the progress of the recharging operation when the remote control device 32 is attached. When the remote control device 32 is not attached to the charging station 50, LED 404 can be used as an indicator of the current charging status of the rechargeable power supply 180 of the remote control device 32. Therefore, LED 404 can indicate the charging status of the rechargeable power supply 180 when the charging station 50 is charging the rechargeable power supply 180 and during the use of the remote control device 32 (i.e., when an operator is using the remote control device 32 to assist in performing work operations). In one exemplary embodiment, LED 404 may include a series of lights, each light representing the charging status level of the rechargeable power supply 180.

[0129] exist Figure 12 and Figure 14 The image shows an exemplary location of the second present contact 222 within the charging station 50. It should be noted that... Figures 12-14 The remote control device 32 shown is Figures 4-7 The single-finger embodiment. It should also be noted that the charging contact 210 and the first present contact 212 in both the single-finger and two-finger embodiments can be arranged as mirror images of each other. Therefore, the same charging station 50 can be used for instances of either the single-finger or two-finger remote control device 32.

[0130] Charging station 50 can be located at various locations on vehicle 10. Its location should be such that it does not interfere with the normal operation of vehicle 10, but is accessible and convenient for the operator. In an embodiment, charging station 50 is located in operator station 20 (see [link]). Figure 1 and Figure 2 The charging station 50 is located in the operator station 20, but can also be accessed from outside the vehicle 10, on the surface of one side of the vehicle 10, or, in the case of inductive charging, within the steering controls of the vehicle 10.

[0131] Charging station 50 may include a voltage regulator (not shown) that converts the power received by charging station 50 from vehicle 10 into a regulated direct current (DC) voltage signal selected based on the charging characteristics of rechargeable power supply 180. For example, in an embodiment where rechargeable power supply 180 is the aforementioned AVX supercapacitor or equivalent device, a 3V DC (1%) power supply voltage may be provided to current limiter 406.

[0132] It should be noted that the remote control device 32 is described herein as having an exemplary configuration and may be structurally modified without departing from the spirit and scope of the invention. For example, one or more components of the remote control device 32 may be combined in a single integral component, or the components may be replaced with alternative components that achieve a similar / identical purpose.

[0133] In one embodiment, the rechargeable power supply 180 is charged via the charging station 50 when one or more charging contacts 210 engage with the corresponding charging element 220 of the charging station 50. In some embodiments, there are at least two or at least four charging contacts 210 and corresponding charging elements 220. In some embodiments, one or more pairs of charging contacts 210 are provided, wherein at least one charging contact 210 in each pair must engage with the corresponding charging element 220 for charging. As described above, at least one of the remote control device 32 and the charging station 50 may include, for example, a second presence contact 222 (such as a switch). The second presence contact 222 detects whether at least one charging contact 210 is correctly engaged with at least one corresponding charging element 220 to charge the rechargeable power supply 180, wherein if correct engagement is detected, then the charging station 50 enables the transfer of power to the rechargeable power supply 180, and if correct engagement is not detected, then the charging station 50 does not enable the transfer of power to the rechargeable power supply 180.

[0134] Furthermore, the arrangement of the remote control device 32 and the charging station 50 is configured such that the second presence contact 222 instructs the remote control device 32 to be removed from the charging station 50, which stops the transfer of power from the charging station 50 to the rechargeable power source 180 before at least one charging contact 210 disengages from at least one corresponding charging element 220. Therefore, the transfer of power from the charging station 50 to the rechargeable power source 180 is stopped before at least one charging contact 210 disengages from at least one corresponding charging element 220. This can be achieved, for example, by setting the height of the charging element 220 and the second presence contact 222, such as... Figure 8A As shown, when the remote control device 32 is inserted into the charging station 50, the charging element 220 is pushed down into the corresponding element housing 220A before the second presence contact 222 engages with the first presence contact 212.

[0135] Figure 15 This is a block-level functional diagram of the portion 450 of the remote control device 32 related to recharging the rechargeable power supply 180. Other portions of the remote control device 32 (such as, for example, those related to mechanical actuators) are not shown in the diagram. Figure 15 As depicted above, the remote control device 32 may include one or more charging contacts 210 configured to engage a corresponding charging element. In some embodiments, the charging element may be a charging element 220 of the charging station 50. In other embodiments, the charging element may be a charging element of an adapter connected to a power source to recharge the rechargeable power supply 180.

[0136] The remote control device 32 may include a protection circuitry 452 that limits electrical parameters such as voltage and / or current within a desired operating range. A charge controller and disconnect circuitry 454 may monitor the voltage received from the protection circuitry 452 and monitor the current charging state of the rechargeable power supply 180 to determine when to stop charging the rechargeable power supply 180. For example, according to an exemplary embodiment, the charge controller and disconnect circuitry 454 may operate to stop further charging when the charge on the rechargeable power supply 180 reaches 3V. The charge controller and disconnect circuitry 454 may include temperature sensing capability or be connected to a temperature sensor, allowing the rechargeable power supply 180 to be charged (or discharged) to different charging levels. In some embodiments, if the sensed temperature is determined to be above a predetermined setpoint temperature, the rechargeable power supply 180 is discharged to a high-temperature charging state, for example, below a fully charged state. In one exemplary aspect of the invention, the sensed temperature is ambient temperature. Alternatively, the sensed temperature is the battery temperature. In some embodiments, if the sensed temperature is determined to be above a predetermined threshold temperature, the rechargeable power supply 180 is charged at the charging station 50 to a predetermined charge level below 100% charge. This helps prevent damage or degradation of the rechargeable power supply 180.

[0137] like Figure 15 As shown, the remote control device 32 may include a wireless communication system 456, such as a BLE radio transceiver that can communicate with the BLE radio transceiver 402 of the charging station 50 via a BLE connection. The wireless communication system 456 and / or the BLE radio transceiver 402 of the charging station 50 may be configured to enter a low-power mode, for example, when the remote control device 32 is paired with the vehicle 10 and / or the rechargeable power supply 180 of the remote control device 32 is being charged at the charging station 50. This ensures that only remote control devices 32 within a minimum distance of the charging station 50 (e.g., less than five inches or less than three inches corresponding to the signal strength of the communication received from the remote control device 32) are identified as remote control devices 32 to be paired. Furthermore, if the BLE radio transceiver 402 of the charging station 50 needs to identify two or more remote control devices 32 that can be used for pairing and cannot determine the correct remote control device for pairing, then the charging station 50 cannot pair with any of the available remote control devices 32 and may require the operator to repeat the pairing process.

[0138] Associate / pair remote control devices with vehicles

[0139] Figures 16-18 Details of an exemplary pairing process according to various aspects of the present invention are illustrated. The remote control device 32 and vehicle 10 described above will be used to describe... Figures 16-18The pairing process is straightforward, but it should be understood that, according to the present invention, other configurations / styles of the remote control device and the vehicle can also be paired together.

[0140] refer to Figure 16 When the vehicle operator retrieves the remote control device 32 at point 502, method 500 begins. If the remote control device 32 is as follows: Figure 4 -Figure 8 and Figures 9-10 In the wearable device of the embodiment, the remote control device 32 is also worn by the operator, for example by securing the retaining strap 190 to one or more of the operator's fingers.

[0141] Then, the vehicle operator initiates a power-on sequence to enable vehicle 10 to operate; that is, the operator starts vehicle 10 at point 504. When starting vehicle 10, the operator may be required to provide login information to vehicle 10. This information can be provided, for example, by entering a personal identification number (PIN) into the control panel of vehicle 10, by providing a login ID to vehicle 10 using a key card, or the operator's PIN can be encoded into a memory device (such as a radio frequency identification (RFID) chip integrated into remote control device 32).

[0142] Then, at point 506, the operator begins the pairing process with vehicle 10, and at point 508, the pairing system 34 pairs the remote control device 32 used by the operator with vehicle 10. (See below for reference.) Figure 17 and Figure 18 The details of two exemplary pairing operations are described in detail.

[0143] Once paired, system 8 can provide visual indications, such as by displaying a message on vehicle 10, illuminating LED 424 in a predetermined color, or creating an auditory or visual queue to indicate that pairing is complete.

[0144] According to one aspect of the invention, the remote control device 32 can be unpaired from the vehicle 10 by turning off the power to the vehicle 10. Other exemplary methods for unpairing the remote control device 32 from the vehicle 10 are described below in exemplary use cases.

[0145] Regarding respectively Figure 17 and Figure 18 Describe the operation of two example pairing systems 34. Figure 17 and Figure 18 These are flowcharts of example methods 550 and 600 for pairing vehicle 10 and remote control device 32 using pairing system 34, which is part of charging station 50 on vehicle 10. Figure 17 and Figure 18 The descriptions of methods 550 and 600 begin with the remote control device 32 being inserted into the charging station 50, and... Figure 16Step 506 corresponds to this.

[0146] refer to Figure 17 In method 550, at 552, when the remote control device 32 is inserted into the charging station 50, the second presence contact 222 is engaged by the first presence contact 212, and the BLE radio transceiver 402 of the charging station 50 is activated to begin scanning or listening for nearby BLE transmissions. As discussed above, the engagement of the first presence contact 212 with the second presence contact 222 can also activate the current limiter 406, allowing power from the vehicle 10 to be supplied from the charging element 220 to the charging contact 210, which will recharge the rechargeable power supply 180 of the remote control device 32. Thus, the pairing and charging operations are initiated by a single action of coupling the remote control device 32 to the charging station 50. Instead of using BLE transmission to pair the remote control device 32 with the vehicle controller 103, the remote control device 32 can be paired with the vehicle controller 103 via, for example, direct physical contact between the charging contact 210 and the charging element 220. Alternatively, dedicated pairing contacts (not shown) can be provided on the remote control device 32 and the vehicle 10 (e.g., at the charging station 50) to pair the remote control device 32 with the vehicle controller 103 via direct physical contact. These pairing contacts on the remote control device 32 and the vehicle 10 can engage with each other while the charging contact 210 engages with the charging element 220, allowing the pairing process to occur simultaneously with the charging process. These pairing contacts can also be used individually to perform message exchange for pairing operations.

[0147] According to one aspect of the invention, when the pairing process is completed wirelessly, at 554, the remote control device 32 detects the presence of voltage at its charging contact 210 and begins transmitting a BLE notification via the wireless transmitter 178 indicating that the remote control device 32 is available to communicate with nearby devices.

[0148] In response, the BLE radio transceiver 402 of charging station 50 can receive one of the transmitted notifications and, at 556, issue a BLE scan request to the specific remote control device 32 associated with the received notification. If the BLE radio transceiver 402 of charging station 50 is to identify two or more remote control devices 32 available for pairing, i.e., by receiving BLE notifications from two or more remote control devices 32 while scanning or listening to nearby BLE transmissions, vehicle 10 cannot pair with any of the available remote control devices 32 and may require the operator to repeat the pairing process by removing the remote control device 32 from charging station 50 and then reinserting the remote control device 32 into charging station 50.

[0149] At point 558, remote control device 32 responds to the scan request with a unique identifier received by BLE radio transceiver 402.

[0150] At point 560, vehicle 10 verifies the code and instructs BLE radio transceiver 402 to open the BLE connection and begin communication with remote control device 32.

[0151] At point 562, once a communication session is established between the remote control device 32 and the charging station 50, a predetermined pairing algorithm can be implemented between the remote control device 32 and the charging station 50 to complete the pairing operation at point 564. Once paired, the vehicle 10 communicates wirelessly with the remote control device 32, and the controller 103 of the vehicle 10 is able to respond to wireless requests received from the remote control device 32.

[0152] In the above about Figure 17 In the example flowchart described, a similar approach can be performed to pair the remote control device 32 with the vehicle 10 using, for example, one or more of the charging elements 220 of the charging station 50 and the charging contacts 210 of the remote control device 32 or the aforementioned dedicated pairing contacts. Instead of transmitting and receiving messages via a wireless / BLE radio transceiver, messages of the same or equivalent type can be communicated via various protocols through the elements / contacts 220 / 210. Messages can be modulated and transmitted on one of the elements / contacts 220 / 210 that provide voltage. In either case, pairing of the vehicle 10 and the remote control device 32 can occur simultaneously with charging of the rechargeable power supply 180 of the remote control device 32.

[0153] refer to Figure 18In method 600, at 602, when the second presence contact 222 is engaged by the first presence contact 212 when the remote control device 32 is inserted into the charging station 50, the BLE radio transceiver 402 of the charging station 50 is enabled for a predetermined timeout (e.g., 1500 ms) to begin scanning or listening for nearby BLE transmissions from the remote control device 32. As discussed above, the engagement of the first presence contact 212 with the second presence contact 222 can also enable the current limiter 406, allowing power from the vehicle 10 to be supplied from the charging element 220 to the charging contact 210, which will charge the rechargeable power supply 180 of the remote control device 32. Thus, the pairing and charging operation is initiated by a single action of coupling the remote control device 32 to the charging station 50, such that components of the remote control device 32 physically contact components of the charging station 50. Instead of using BLE transmission to pair the remote control device 32 with the vehicle controller 103, the remote control device 32 can pair with the vehicle controller 103 via, for example, direct physical contact between the charging contact 210 and the charging element 220. Alternatively, dedicated pairing contacts (not shown) can be provided on the remote control device 32 and the vehicle 10 (e.g., at the charging station 50) to pair the remote control device 32 with the vehicle controller 103 via direct physical contact. Such pairing contacts on the remote control device 32 and the vehicle 10 can engage with each other concurrently with the charging contact 210 to the charging element 220, allowing the pairing process to occur simultaneously with the charging process. These pairing contacts can also be used individually to perform message exchange for pairing operations.

[0154] At 604, the signal strength of the BLE transmission between the wireless transmitter 178 and the BLE radio transceiver 402 can be reduced during the pairing process to help prevent any other nearby vehicle 10 from receiving BLE transmissions from the remote control device 32.

[0155] According to one aspect of the invention, when the pairing process is completed wirelessly, at 606, the remote control device 32 detects the presence of voltage at its charging contact 210 and begins transmitting a BLE notification via the wireless transmitter 178 at a predetermined rate (e.g., 20ms rate) for a preset timeout (e.g., 2000ms timeout), indicating that the remote control device 32 is available to communicate with the nearby vehicle 10. If the BLE radio transceiver 402 of the charging station 50 is to identify two or more remote control devices 32 available for pairing, i.e., by receiving BLE notifications from two or more remote control devices 32 while scanning or listening for nearby BLE transmissions, the vehicle 10 cannot pair with any of the available remote control devices 32 and can request the operator to repeat the pairing process by removing the remote control device 32 from the charging station 50 and then reinserting the remote control device 32 into the charging station 50.

[0156] Before sending a BLE announcement from the wireless transmitter 178, the charging station 50 can provide power to recharge the rechargeable power supply 180 for up to approximately, for example, 1000 ms. The charging of the rechargeable power supply 180 by the charging station 50 will be discussed in detail below.

[0157] In response to receiving a BLE notification from the wireless transmitter 178, at 608, the BLE radio transceiver 402 of the charging station 50 can issue a BLE scan request.

[0158] At 610, the remote control device 32 receives a scan request from the BLE radio transceiver 402 and uses the address of the BLE radio transceiver 402 to create a unique identifier, which is then sent back to the BLE radio transceiver 402 at 612.

[0159] At step 614, vehicle 10 verifies the code and instructs BLE radio transceiver 402 to open the BLE connection and begin communication with remote control device 32. It is important to note that if vehicle 10 receives more than one valid identification code during step 614—for example, if vehicle 10 receives identification codes from two different remote control devices 32—pairing will fail, vehicle 10 will issue an error message or other warning, and the operator will be instructed to repeat the pairing process by removing remote control device 32 from charging station 50 and then reinserting it into charging station 50.

[0160] At 616, once a communication session is established between the remote control device 32 and the charging station 50, the pairing operation can be completed, and at 618, the signal strength of the BLE transmission between the wireless transmitter 178 and the BLE radio transceiver 402 can be increased and restored to normal levels.

[0161] At 620, the operator can be asked to perform an action as a test to confirm that the remote control device 32 is working and can communicate with the charging station 50, such as by pressing a sequence of buttons on the remote control device 32, for example by pressing the horn button 197B and the brake button 197C simultaneously.

[0162] Once paired, vehicle 10 communicates wirelessly with remote control device 32, and the controller 103 of vehicle 10 is able to respond to wireless requests received from remote control device 32.

[0163] According to various aspects of the invention, the pairing period (which is the time spent establishing communication between the remote control device 32 and the vehicle 10, beginning with step 552 / 602 and ending with step 564 / 616) can be shorter than the charging period (which is the time spent charging the rechargeable power supply 180 to the desired charging state at the charging station 50), wherein will be combined below Figure 21 and 22 The charging of the rechargeable power supply 180 is discussed.

[0164] refer to Figure 19 According to another aspect of the invention, after performing work operations, the vehicle operator may need to temporarily leave the vehicle 10, for example, to take a break. An exemplary method 700 is shown for shutting down and restarting the vehicle 10 and re-pairing the vehicle 10 with the remote control device 32 used by the operator. At 702, the operator shuts off the power to the vehicle 10 to take a break, etc. After a period of time, the vehicle operator reconnects the power to the vehicle 10. During this break, the remote control device 32 can continue to pair with the vehicle 10 for a predefined period of time. This state of pairing between the vehicle 10 and the remote control device 32 can be indicated, for example, by illuminating an LED 424 with a predetermined color, pattern, etc., on a touchscreen (not shown) provided on the vehicle 10. Therefore, if at 704 the operator powers on the vehicle 10 before the predefined period of time expires, then at 706 the vehicle 10 can detect the remote control device 32, whereby the remote control device 32 remains paired with the vehicle 10. At this point, the operator may or may not have to take some kind of action at 708, such as by pressing a button on the vehicle 10 (e.g., on the charging station 50, on the touchscreen, etc.) or by pressing a sequence of buttons on the remote control device 32.

[0165] A successful operator action at 708 results in confirmation of pairing between remote control device 32 and vehicle 10 at 710. The visual queue can be displayed on an indicator (LED 424) to indicate pairing, for example, by illuminating LED 424 in the second color described above.

[0166] Alternatively, according to this aspect of the invention, if the operator supplies power to the vehicle 10 after a predefined time period at 712 has elapsed, the operator may be required to re-pair the remote control device 32 to the vehicle 10 as initially paired, for example by plugging the remote control device 32 into the charging station 50 at 714.

[0167] refer to Figure 20An exemplary method 800 is shown for re-establishing communication between the remote control device 32 and the vehicle 10 after a period of inactivity. At 802, the controller 103 on the vehicle 10 detects that no vehicle-related activity has been performed within a given time period after communication between the remote control device 32 and the vehicle 10 was established. Exemplary vehicle-related activities include driving the vehicle 10 (or manually driving using manual controls in the operator station 20, other manual controls (e.g., on the side of the vehicle 10), or via the remote control device 32), standing on the platform 21, moving or placing items on the load handling assembly 12, etc. At 804, if no vehicle-related activity has occurred for a first predetermined amount of time after communication between the remote control device 32 and the vehicle 10 was established, then communication between the remote control device 32 and the vehicle 10 is terminated and must be re-established at 806 using the pairing system 34, i.e., by inserting the remote control device 32 into the charging station 50 at the vehicle 10. This terminated pairing status between vehicle 10 and remote control device 32 can be indicated on a touchscreen, for example, by illuminating LED 424 with a predetermined color, pattern, etc.

[0168] At point 808, if no vehicle-related activity occurs within a second predetermined time period after communication is established between the remote control device 32 and the vehicle 10, where the second predetermined time period is equal to or less than the first predetermined time period, then communication between the remote control device 32 and the vehicle 10 is terminated. However, it can be re-established without the pairing system 34, for example, by performing a confirmation method using the remote control device 32 at point 810. The confirmation method may include, for example, the operator performing a sequence of buttons on the remote control device 32, such as by pressing and holding one or more of buttons 197A-C. This pairing status between the vehicle 10 and the remote control device 32 can be indicated on the touchscreen, for example, by illuminating LED 424 with a predetermined color, pattern, etc.

[0169] Figure 21 This is a flowchart of an example method 900 for charging a remotely controlled device according to the principles of the present invention. In particular, the remotely controlled device may be the same as or similar to the remotely controlled device 32 discussed herein, and may include a wireless communication system 456 comprising a wireless transmitter 178 (e.g., capable of one-way or two-way communication), a rechargeable power supply 180, and at least one control (e.g., controls 196A-C) that enables the wireless transmitter 178 to wirelessly transmit requests to a controller of the material handling vehicle 10.

[0170] A method 900 for charging a remote control device 32 begins at 902 by initiating contact between a component of the remote control device 32 and an element of a charging station 50 located at the vehicle 10, and then senses the contact between the remote control device component and the charging station element. As described above, the remote control device 32 may include one or more charging contacts 210, each charging contact 210 being arranged to engage a corresponding charging element 220 of the charging station 50, such that when they engage, a second presence contact 222 or similar device engages a corresponding first presence contact 212 to detect or sense contact between (one or more) charging contacts 210 and (one or more) charging elements 220. However, other components of the remote control device 32 and other elements of the charging station 50 may be used to initiate the detection / sensing of contact.

[0171] Next, at 904, a charging period begins, during which power is supplied from charging station 50 to rechargeable power source 180. As described above, as an example, the circuitry of charging station 50 is configured such that upon sensing contact between charging contacts(one or more) and charging elements(one or more) 220, power is supplied from charging station 50 to charging contacts 210 of remote control device 32 to charge rechargeable power source 180. Once rechargeable power source 180 is substantially fully charged (or charged to a desired amount less than substantially fully charged), remote control device 32 can be removed from charging station 50.

[0172] therefore, Figure 21 The method continues at 906, interrupting the contact between the remote control device component and the charging station component, and sensing the interruption of the contact between the remote control device component and the charging station component. As described above, the charging contacts 210(s) of the remote control device 32 and the charging elements 220(s) of the charging station 50 are arranged such that the state can be detected or sensed when the two systems are disconnected. An example is a second presence contact 222 that can detect when the remote control device 32 is removed from the charging station 50.

[0173] Finally, upon sensing this interruption at 906, charging station 50 can stop supplying power from charging station 50 to rechargeable power source 180 at 908, thereby ending the charging period. It should be noted that the second presence contact 222 can be located on remote control device 32, and its disengagement can cause a stop in supplying power from charging station 50 to rechargeable power source 180. Supplying power from charging station 50 to rechargeable power source 180 can also be stopped when rechargeable power source 180 is charged to a desired amount (or fully charged or charged to a desired amount less than fully charged), as described herein.

[0174] Method 900 may include Figure 21Other optional steps are shown. For example, method 900 may further include confirming the establishment of communication between remote control device 32 and vehicle 10 at 910, for example, using at least one of auditory or visual queues. Method 900 may further include establishing communication (e.g., pairing) between remote control device 32 and vehicle 10 at 912 during a pairing period when the remote control device component contacts a charging station element, such that controller 103 receives transmissions from remote control device 32 and is able to fulfill wireless requests from remote control device 32. Such communication between remote control device 32 and vehicle 10 may be established concurrently during charging of rechargeable power supply 180 at charging station 50, such that pairing periods overlap with charging periods. In at least some embodiments, the pairing period is less than or equal to the charging period.

[0175] Furthermore, method 900 may include, at 914, displaying the charging status of the rechargeable power supply 180 at vehicle 10 (e.g., at charging station 50), wherein the charging status of the rechargeable power supply 180 can be displayed at vehicle 10 while the rechargeable power supply 180 is being charged and while using remote control device 32. The charging status of the rechargeable power supply 180 may be displayed, for example, via a series of lights, each light representing the level of the charging status of the rechargeable power supply 180.

[0176] Figure 22 This is a flowchart of another example method 950 for charging a remotely controlled device (such as remotely controlled device 32 discussed herein) according to the principles of the present invention. The remotely controlled device includes a wireless communication system 456 comprising a wireless transmitter 178 (e.g., capable of one-way or two-way communication), a rechargeable power supply 180, and at least one control (e.g., controls 196A-C) that enables the wireless transmitter 178 to wirelessly transmit requests to a material handling vehicle 10. As used herein, the term "control" in describing the controls of remotely controlled device 32 means any structure capable of providing the desired function, including but not limited to buttons, switches, dials, etc.

[0177] The method 950 for charging the remote control device 32 begins at 952 by initiating contact between a component of the remote control device 32 and an element of a charging station 50 located at the vehicle 10, and then senses the contact between the remote control device component and the charging station element. As described above, the remote control device 32 may include one or more charging contacts 210, each charging contact 210 being arranged to engage a corresponding charging element 220 of the charging station 50, such that when they engage, a second presence contact 222 or similar device engages a corresponding presence contact 212 to detect or sense contact between (one or more) charging contacts 210 and (one or more) charging elements 220. However, other components of the remote control device 32 and other elements of the charging station 50 may be used to initiate the detection / sensing of contact.

[0178] At step 954, the current charging state of the rechargeable power supply 180 is determined. Step 954 can be performed before or after step 952; that is, the charging state of the rechargeable power supply 180 can be transmitted to the charging station 50 when the remote control device 32 is coupled to the charging station 50 and while the remote control device 32 is being used by an operator, as discussed herein.

[0179] Based on the current charging state of the rechargeable power supply 180 and after executing step 952, at 956, a charging period begins, during which power is supplied from the charging station 50 to the rechargeable power supply 180. In one exemplary embodiment, at step 958A, if the voltage of the rechargeable power supply 180 is below a voltage threshold VT, then the charging station 50 charges the rechargeable power supply 180 at a higher first power level PL1. According to this embodiment, at step 958B, if the voltage of the rechargeable power supply 180 is above the voltage threshold VT, then the charging station 50 charges the rechargeable power supply 180 at a lower second power level PL2. In either case (i.e., at step 958A or step 958B), the resulting charging period can be approximately the same; that is, charging the rechargeable power supply 180 from above or below the voltage threshold VT to the desired amount can take approximately the same amount of time. Although this paper only discusses two power levels PL1, PL2 associated with a single voltage threshold VT, additional voltage thresholds and power levels can be used, where the charging period can always be approximately the same, regardless of the charging level when the rechargeable power supply 180 is plugged into the charging station 50. Furthermore, the power level can be dynamically set based on the current charging state of the rechargeable power supply 180 using equations.

[0180] Once the charging period is complete (i.e., once the rechargeable power supply 180 has been charged to the desired amount, namely, substantially fully charged or charged to an amount less than substantially fully charged, for example, given the sensed temperature if the technology is present in system 8, or if less than fully charged is desired), the remote control device 32 can be removed from the charging station 50.

[0181] therefore, Figure 22 The method continues at 960, interrupting the contact between the remote control device component and the charging station component, and sensing the interruption of the contact between the remote control device component and the charging station component. As described above, the charging contacts 210(s) of the remote control device 32 and the charging elements 220(s) of the charging station 50 are arranged such that the state can be detected or sensed when the two systems are disconnected. An example is a second presence contact 222 that can detect when the remote control device 32 is removed from the charging station 50.

[0182] Finally, after this interruption is sensed at 960, or after the rechargeable power supply 180 has been charged to the desired amount, the charging station 50 can stop supplying power from the charging station 50 to the rechargeable power supply 180 at 962, thereby ending the charging period.

[0183] Method 950 may include Figure 22 Other optional steps are shown. For example, method 950 may also include confirming the establishment of communication between remote control device 32 and vehicle 10 at 964, for example, using at least one of auditory or visual queues. Method 950 may also include establishing communication (e.g., pairing) between remote control device 32 and vehicle 10 during a pairing period at 966 when the remote control device component contacts the charging station element, such that controller 103 receives transmissions from remote control device 32 and is able to fulfill wireless requests from remote control device 32. Such communication between remote control device 32 and vehicle 10 may be established concurrently during charging of rechargeable power supply 180 at charging station 50, such that the pairing period overlaps with the charging period. In at least some embodiments, the pairing period is less than or equal to the charging period, but the pairing period may be longer than the charging period, as will be discussed in more detail below.

[0184] Furthermore, method 950 may include, at 968, displaying the charging status of the rechargeable power supply 180 at vehicle 10 (e.g., at charging station 50), wherein the charging status of the rechargeable power supply 180 can be displayed at vehicle 10 while the rechargeable power supply 180 is being charged and while using remote control device 32. The charging status of the rechargeable power supply 180 may be displayed, for example, via a series of lights, each light representing the level of the charging status of the rechargeable power supply 180.

[0185] According to one aspect of the invention, the charging period can depend on the capacity of the rechargeable power supply 180, the charging rate / power level supplied by the charging station 50, and / or the charging state of the rechargeable power supply 180 when inserted into the charging station 50. Therefore, when the remote control device 32 is placed in the charging station 50, the desired charging period can be achieved regardless of the current charging state of the rechargeable power supply 180. For example, the current charging state of the rechargeable power supply 180 can be known to the vehicle 10, and for example, the charging state of the rechargeable power supply 180 can be transmitted to the charging station 50, as discussed herein. The charging station 50 can, for example, be instructed by the controller 103 to supply power to the rechargeable power supply 180 at different rates or levels based on the charging state of the rechargeable power supply 180 when the remote control device 32 is placed in the charging station 50, such that when the remote control device 32 is placed in the charging station 50, the charging period is generally approximately the same regardless of the charging state of the rechargeable power supply 180. For example, as referenced above... Figure 22 As discussed in steps 958A / B, if the charging state of the rechargeable power supply 180 is a lower first charging state, then a higher first power ratio / power level can be provided to the rechargeable power supply 180 from the charging station 50. If the charging state of the rechargeable power supply 180 is a higher second charging state, then a lower second power ratio / power level can be provided to the rechargeable power supply 180 from the charging station 50. In both cases, the resulting charging period can be approximately the same, for example, within approximately 0.5 seconds of the desired charging period. Any number of rechargeable power supply charging states and corresponding power rates / levels can be achieved such that the time required to charge the rechargeable power supply 180 is within the desired charging period. Furthermore, the rechargeable power supply 180 can have its lifespan increased when charged at a lower power level. Therefore, an additional advantage of the consistent charging period, as with the present invention, is that the rechargeable power supply 180 is sometimes charged at a lower power level, for example, when the charging state of the rechargeable power supply 180 when plugged into the charging station 50 is the higher second charging state discussed above. Therefore, in contrast to the case where the rechargeable power supply 180 is charged at a consistent, higher power level each time it is charged, charging the rechargeable power supply 180 at different power levels, as discussed herein, can increase the lifespan of the rechargeable power supply 180.

[0186] Furthermore, although the pairing period, described herein as the time taken to establish communication between the remote control device 32 and the vehicle 10, can be less than or equal to the charging period, the charging period can also be less than the pairing period. As an example, it can be determined that the rechargeable power supply 180 does not need to be fully charged to operate during the desired usage period. For example, a fully charged rechargeable power supply 180 could provide operating time greater than the desired usage period (e.g., an operator's shift), allowing the rechargeable power supply 180 to operate during the desired usage period without being fully charged. In this case, the charging station 50 can be programmed to charge the rechargeable power supply 180 to a state below full charge, which is sufficient for the remote control device to remain operational throughout the desired usage period. The time taken to charge the rechargeable power supply 180 to this state below full charge can be less than the pairing period. Other situations where the charging period can be less than the pairing period may also occur.

[0187] refer to Figure 23 The principle of this invention can also be implemented as a kit 1000 for modifying material handling vehicles 10'. Figure 23 In the middle, with reference above Figures 1-22 Those similar or identical elements described include the same reference numerals, followed by an apostrophe ('). Regarding Figure 23 Described but not in Figure 23 The elements specifically shown are equivalent to those with the same reference numerals as described above but without apostrophes.

[0188] Vehicle 10' may include vehicle controller 103', which responds to wireless requests from associated remote control device 32' used by an operator interacting with vehicle 10', similar to those types of vehicles 10 and remote control devices 32 described above. Example kit 1000 will include a charging station 50' located at vehicle 10', a charging station 50' for charging a rechargeable power supply 180' of remote control device 32', wherein charging station 50' is electrically coupled to the vehicle power supply, and a receiver 102' (such as a BLE radio transceiver) communicatively coupled to controller 103' of vehicle 10'. Specifically, charging station 50' is configured such that rechargeable power supply 180' is charged to a desired amount (fully charged or less than fully charged, as discussed herein) at charging station 50' during a desired charging period.

[0189] Kit 1000 may also include a pairing system 34' for establishing communication between the remote control device 32' and the vehicle 10', enabling the controller 103' to respond to wireless requests from the remote control device 32'. The pairing system 34' may be, for example, similar to pairing system 34 and may implement... Figure 17 and / or Figure 18The pairing algorithm(s) detailed in the description are described below. Therefore, kit 1000 may also include a pairing indicator, such as a visual indicator 424', which confirms the establishment of communication between the remote control device 32' and the vehicle 10'. Furthermore, the pairing system 34' may be configured such that the pairing period (the time taken to establish communication between the remote control device 32' and the vehicle 10') can be less than or equal to the charging period (the time taken to charge the rechargeable power supply 180' to the desired amount). The pairing period may also be longer than the charging period. The pairing system 34' may be integrated into the charging station 50' or may be a separate component.

[0190] It is anticipated that communication between the remote control device 32' and the vehicle 10' will be established concurrently during the charging of the rechargeable power supply 180' at charging station 50', i.e., the pairing period and the charging period may overlap. Furthermore, in some embodiments, the communication between the remote control device 32' and the vehicle 10', as well as the charging of the rechargeable power supply 180' at charging station 50', is initiated by a single action. For example, the single action may include physically contacting a component of the remote control device (e.g., one or more charging contacts 210 as described above) with an element of the charging station (e.g., one or more corresponding charging elements 220), as described above.

[0191] The remote control device 32' used in conjunction with kit 1000 can be the same as the remote control device 32 disclosed herein. Therefore, a remote control device manufactured for use with vehicle 10 including integrated charging station 50 and related components can also be used with kit 1000 for existing vehicle 10'.

[0192] As described above regarding charging station 50, the charging station 50' of kit 1000 may also include a guide structure 420' to align the remote control device 32' in the appropriate orientation to charge the rechargeable power supply 180'.

[0193] Kit 1000 may also include an indicator (e.g., LED 404', a lamp, or similar structure) configurable to be attached to vehicle 10' for indicating the charging status of rechargeable power supply 180'. The indicator can indicate the charging status of rechargeable power supply 180' while charging station 50' is charging rechargeable power supply 180' and during use of remote control device 32'. In some embodiments, the indicator includes a series of lights, each light representing a charging status level of rechargeable power supply 180'.

[0194] The kit 1000 includes at least one charging element 220' on a charging station 50', which engages with at least one corresponding charging contact 210' of a remote control device 32'. Furthermore, at least one of the remote control device 32' or the charging station 50' includes a presence contact 212' or 222' that detects whether at least one corresponding charging contact 210' and at least one charging element 220' are correctly engaged with each other. If correct engagement is detected, then the charging station 50' initiates the delivery of power to the rechargeable power source 180' of the remote control device 32'; if correct engagement is not detected, then the charging station 50' does not enable the delivery of power to the rechargeable power source 180'. In at least some embodiments, the remote control device 32' includes at least two or at least four charging contacts 210' positioned to engage the corresponding charging element 220' on the charging station 50'.

[0195] The arrangement of the remote control device 32' and the charging station 50' in the kit 1000 is configured such that the presence of contacts 212' or 222' instructs the remote control device 32' to be removed from the charging station 50', which stops the power transfer from the charging station 50' to the rechargeable power source 180' before at least one charging contact 210' disengages from at least one corresponding charging element 220'. Therefore, the power transfer from the charging station 50' to the rechargeable power source 180' is stopped before at least one charging contact 210' disengages from at least one corresponding charging element 220'.

[0196] Kit 1000 can also utilize contactless or inductive charging, wherein the rechargeable power supply 180' of the remote control device 32' can be charged by proximity to or on a compatible inductive charging station (not shown). For example, such an inductive charging station could be located in the driving or steering controls of vehicle 10', allowing the rechargeable power supply 180' to be charged while the operator manually drives vehicle 10' from operating station 20'. Kit 1000 according to this aspect of the invention can be at least partially located in the vehicle steering controls or other vehicle components that facilitate contactless / inductive charging of the rechargeable power supply 180', for example, by the operator gripping the driving / steering controls.

[0197] Kit 1000 can utilize the above-mentioned... Figures 1-22Any other features and / or functions of the described remote control device 32' and charging station 50'. It should be noted that if the vehicle 10' used with kit 1000 was previously configured to interact with the wireless remote control device, the controller logic in vehicle controller 103' may need to be updated for use with kit 1000, and the receiver already provided on vehicle 10' (i.e., used to receive wireless requests from the remote control device used with vehicle 10' before kit 1000 is installed on vehicle 10') can be disabled to be replaced by receiver 102' of kit 1000 (i.e., used with remote control device 32' associated with kit 1000).

[0198] Now for reference Figure 24 According to an embodiment of the invention, the remote control device 32 can be incorporated into the glove garment 1100. The use of the glove garment 1100 eliminates the need for the retaining strap 190, and the first control 196A can be provided on the fingers of the glove garment 1100, rather than as part of the upper housing 174, but... Figure 24 The remaining components of the remote control device 32 shown can be connected to Figures 4-7 The components of the remote control device 32 are the same or similar, including the shape of the upper housing 174 that engages with the charging station 50 at the vehicle 10. Therefore, the charging station 50 at the vehicle 10 can be the same as the charging station 50 described above, i.e., the charging station engagement portion of the upper housing 174 of the remote control device 32, which is integrated into the glove garment 1100, can have a shape similar to that of the charging station 50. Figures 4-7 In the embodiments, the upper housing 174 of the remote control device 32 has the same size as the charging station engagement portion, and the same charging station 50 can be used with or Figures 4-7 Install remote control device 32 on the finger or combine it with Figure 24 The remote control device 32 is used in the gloves and clothing 1100.

[0199] If the remote control device 32 incorporated into the glove garment 1100 is used in conjunction with the inductive charging technology disclosed herein, then the inductive charging structure can be incorporated, for example, into the palm of the hand within the glove garment 1100. This charging structure in the glove garment 1100 can be used with charging elements, for example, incorporated into the steering control of a vehicle paired with the remote control device 32, in which case the rechargeable power supply of the remote control device 32 can be charged while the operator holds the steering controls.

[0200] According to an additional aspect of the invention, there may be conditions and / or events that cause vehicle 10 to become unpaired from remote control device 32, wherein, as described herein, it may be required to re-pair vehicle 10 with remote control device 32 using the full pairing process of pairing system 34. Other conditions or events may exist that cause vehicle 10 to become unpaired from remote control device 32, wherein something other than the full pairing process of pairing system 34, as described herein, may be required to re-pair vehicle 10 with remote control device 32. Several exemplary use cases concerning unpairing and re-pairing will now be described.

[0201] A first exemplary use case can occur by turning off the power to vehicle 10. According to this first use case, remote control device 32 unpairs from controller 103 and requests the full pairing process of pairing system 34, as described herein, to repair vehicle 10 with remote control device 32. According to this exemplary first use case, whenever vehicle 10 is powered off, the full pairing process of pairing system 34 can be requested to repair remote control device 32 to vehicle 10.

[0202] The second exemplary use case can be substantially as described above. Figure 19 As described, the vehicle operator temporarily leaves the vehicle 10, for example, to take a break. (See above reference.) Figure 17 The details of this second exemplary use case have been discussed and will not be repeated here.

[0203] If no vehicle-related activity occurs within a first predetermined time period after communication is established between the remote control device 32 and the vehicle 10 (third use case), or if no vehicle-related activity occurs within a second predetermined time period after communication is established between the remote control device 32 and the vehicle 10 (fourth use case), then the third and fourth exemplary use cases may occur. Details of these third and fourth exemplary use cases are referenced above. Figure 20 This has been discussed and will not be repeated.

[0204] In cases involving multiple remote control devices 32 and / or multiple vehicles 10, several exemplary use cases may arise. In a fifth exemplary use case, it is assumed that a first remote control device 32 is currently paired with a first vehicle 10, and a second remote control device 32 is currently paired with a second vehicle 10. In this fifth use case, the first remote control device 32 is plugged into a charging station 50 of the second vehicle 10. In this case, the charging station 50 of the second vehicle 10 can charge the rechargeable power supply 180 of the first remote control device 32, the first remote control device 32 can become unpaired from the first vehicle 10, and the second remote control device 32 can become unpaired from the second vehicle 10. In the fifth use case, the first remote control device 32 will not be paired with the second vehicle 10.

[0205] In the sixth exemplary use case and referring to Figure 24 Assume that remote control device 32 is currently paired with first vehicle 10A, enabling wireless communication between them, and second vehicle 10B is not currently paired with the remote control device. In this sixth use case, remote control device 32 pairs with second vehicle 10B using a pairing process, for example, by inserting remote control device 32 into charging station 50 of second vehicle 10B. Using this pairing process, charging station 50 of second vehicle 10B can charge the rechargeable power supply 180 of remote control device 32, and remote control device 32 can become paired with second vehicle 10B, enabling wireless communication between them. This pairing process also causes remote control device to become unpaired from first vehicle 10A, so that it no longer communicates wirelessly with first vehicle 10A. Once remote control device 32 is paired with second vehicle 10B and unpaired from first vehicle 10A, second vehicle 10B can respond to remote requests from remote control device 32, while first vehicle 10A can no longer respond to remote requests from remote control device 32.

[0206] As described above, the wireless communication system 456 of the remote control device 32 and / or the BLE radio transceiver 402 of the charging station 50 can be configured to enter a low-power mode, for example, when the remote control device 32 is paired with the second vehicle 10B and / or the rechargeable power supply 180 of the remote control device 32 is charging at the charging station 50, to ensure that only the remote control device 32 within a minimum distance from the charging station 50 (corresponding to the signal strength of the communication received from the remote control device 32) is identified as the remote control device 32 to be paired with by the second vehicle 10B.

[0207] According to the sixth exemplary use case, prior to the pairing process, the second vehicle 10B can be sent to a designated location (such as, for example, the operator's location, the location of the first vehicle 10A, the end of the aisle where the operator and / or the first vehicle 10A is located, a designated waiting area, etc.) by a warehouse management system (WMS) communicating with the second vehicle 10B. The second vehicle 10B can be an unloaded vehicle (i.e., without a load), thus ready to carry the items to be picked by the operator. For example, when the first vehicle 10A is loaded with the desired amount of picked items and is ready to be sent to a different location (i.e., a location different from the current location of vehicle 10, such as a loading dock LD or another location where the picked items on the first vehicle 10A will be sent), the second vehicle 10B can be instructed to move to the designated location, for example, via the warehouse management system (WMS). The operator can also request that the second vehicle 10B be sent to the designated location, for example, using controls on the first vehicle 10A, via headphones, etc. Once the second vehicle 10B is paired with the remote control device 32, the second vehicle 10B will no longer be able to execute commands from the warehouse management system (WMS), so that the second vehicle 10B will only implement wireless commands from the remote control device 32 it is paired with.

[0208] Once the remote control device 32 is unpaired from the first vehicle 10A, the warehouse management system (WMS) can send instructions to the first vehicle 10A to move to the loading / unloading dock LD and / or another location (such as a vehicle charging station (not shown)). Using this sixth exemplary use case, operators can quickly switch between vehicles 10A and 10B, thereby improving work productivity and efficiency.

[0209] In the seventh exemplary use case, it is assumed that the first remote control device 32 is currently paired with vehicle 10, while the second remote control device 32 is not paired with the vehicle. In this seventh use case, the second remote control device 32 is plugged into the charging station 50 of vehicle 10. In this case, the charging station 50 of vehicle 10 can charge the rechargeable power supply 180 of the second remote control device 32, the first remote control device 32 can become unpaired from vehicle 10, and the second remote control device 32 will not be paired with vehicle 10.

[0210] In the eighth exemplary use case, the remote control device 32 is removed from the range of the vehicle 10, i.e., the wireless transmitter 178 is no longer able to communicate with the receiver 102 for a predetermined period of time. According to the eighth use case, the remote control device 32 can become unpaired from the vehicle 10. According to the eighth use case, if the remote control device 32 is moved back into the range of the vehicle 10 after the predetermined period of time, the vehicle 10 may need to be turned off and restarted to pair with the remote control device 32 using the pairing system 34, including pairing with a previously paired remote control device 32 or a different remote control device 32. If the remote control device 32 is moved back into the range of the vehicle 10 within the predetermined period of time, the vehicle 10 may not need to be turned off and restarted to pair with the previously paired remote control device 32; for example, the previously paired remote control device 32 can be re-paired with the vehicle 10 by plugging the remote control device 32 into the vehicle's charging station 50. Pairing the vehicle 10 with a different remote control device 32 may require the vehicle to be turned off and restarted, regardless of how long the previously paired remote control device 32 has been outside the range of the vehicle 10.

[0211] Additional exemplary use cases regarding pairing and / or charging periods will now be described.

[0212] In the ninth exemplary use case, the desired state of charge of the rechargeable power supply 180 (e.g., substantially fully charged) can be achieved by charging the rechargeable power supply 180 at the charging station 50 for a period of five seconds or less. According to this use case, the substantially fully charged state of the rechargeable power supply 180 can generate a usage period of at least eight hours for the remote control device 32.

[0213] In the tenth exemplary use case, when the remote control device 32 is inserted into the charging station 50, the charging station 50 changes the power level supplied to the rechargeable power supply 180 according to the charging state of the rechargeable power supply 180 when the remote control device 32 is inserted into the charging station 50, as described herein. Figure 22 As described, regardless of the charging status of the rechargeable power supply 180 when the remote control device 32 is plugged into the charging station 50, the charging period according to the tenth use case will always be approximately four seconds. Therefore, a predictable charging period is achieved.

[0214] It is important to note that the type of transmission sent from the remote control device 32 to the vehicle 10 (e.g., a request, such as a driving request) can be other types of transmissions. As an example, the transmission may include a location-based transmission that informs the controller 103 of the vehicle 10 where the remote control device 32 is located relative to the vehicle 10. These types of location transmissions can be used by the controller 103, for example, to follow the remote control device 32. Thus, the vehicle 10 can follow an operator wearing, holding, or carrying the remote control device 32. This remote control device 32 can be charged by the charging station 50 and paired with the vehicle 10 as described herein.

[0215] According to another aspect of the invention, charging of the rechargeable power supply 180 by the charging station 50 can be disabled when the vehicle 10 is in motion. This aspect of the invention may not be applicable to inductive charging of the rechargeable power supply 180.

[0216] Furthermore, when an operator attempts to pair the remote control device 32 with the vehicle 10, which communicates with the warehouse management system (WMS), the WMS can determine whether one or more remote control device operation checks have been performed within a predetermined time period (e.g., within the most recent 12 hours). Such operation checks may include, for example, checking to ensure the operability of controls on the remote control device 32 (such as the horn and / or brake buttons 197B, 197C). If one or more such operation checks have not been performed within the predetermined time period, the vehicle 10 can communicate to the operator that the operation checks must be performed before pairing the remote control device 32 with the vehicle 10; that is, pairing of the remote control device 32 with the vehicle 10 is only permitted if one or more remote control device operation checks have been performed within the predetermined time period. The operation checks can be performed by the operator implementing the controls, for example, by pressing and holding the horn and / or brake buttons 197B, 197C.

[0217] Furthermore, when an operator attempts to pair remote control device 32 with vehicle 10, which communicates with the warehouse management system (WMS), the WMS can determine whether the operator is authorized to operate the vehicle 10 that the operator is attempting to pair with remote control device 32. For example, a vehicle used only in a specific location (such as in a cold storage facility) can only be paired with remote control device 32 of the vehicle the operator will use at that location. As another example, an operator may be limited to operating only certain vehicles. In these cases, remote control device 32 may be authorized to pair with such vehicles only if one or more of these conditions are met.

[0218] According to one aspect of the invention, when it is determined that an operator is standing on the platform 21 of the vehicle 10, for example as detected by the presence sensor 22, the charging life of the rechargeable power supply 180 in a given operating cycle can be increased by turning off or reducing the power consumption of one or more components of the remote control device 32 (e.g., components of the wireless communication system 456, including the wireless transmitter 178).

[0219] Alternative expressions of the inventive concept and other ways of carrying out the invention are set forth in the following numbered clauses:

[0220] Terms and Conditions

[0221] 1. A system comprising:

[0222] A remote control device, usable by an operator to interact with a material handling vehicle, the remote control device being used to wirelessly control one or more functions of the vehicle, and comprising:

[0223] Wireless transmitter;

[0224] At least one control communicatively coupled to a wireless transmitter, wherein actuation of the control causes the wireless transmitter to wirelessly transmit a request; and

[0225] Rechargeable power supply;

[0226] The receiver at the vehicle is used to receive transmissions from the wireless transmitter;

[0227] A controller at the vehicle location, communicatively coupled to a receiver, which responds to requests received from a remote control device; and

[0228] The charging station at the vehicle location is used to charge the rechargeable power source for remotely controlled devices.

[0229] 2. The system according to Clause 1, wherein the rechargeable power source is a supercapacitor.

[0230] 3. The system according to Clause 1 or Clause 2 further includes a pairing system for establishing communication between the remote control device and the controller, such that the controller will respond to wireless requests from the remote control device.

[0231] 4. The system as described in Clause 3, wherein communication between the remote control device and the controller is currently established during the charging of the rechargeable power supply at the charging station.

[0232] 5. The system described in Clause 3 or Clause 4, wherein communication between the remote control device and the controller, as well as the charging of the rechargeable power supply at the charging station, is initiated with a single action.

[0233] 6. The system according to Clause 5, wherein a single action includes making a component of the remote control device physically contact an element of the charging station.

[0234] 7. The system according to any one of clauses 3 to 6 further includes a pairing indicator that confirms the establishment of communication between the remote control device and the controller.

[0235] 8. A system according to any one of clauses 3 to 7, wherein the time period for establishing communication between the remote control device and the controller is less than or equal to the pairing time period.

[0236] 9. The system according to any one of clauses 1 to 8, wherein the rechargeable power supply is substantially fully charged by charging the rechargeable power supply at a charging station for a period of five seconds or less.

[0237] 10. The system according to Clause 9, wherein a substantially fully charged state of the rechargeable power supply generates a usage period of at least two hours for the remotely controlled device.

[0238] 11. The system according to Clause 10, wherein a substantially fully charged state of the rechargeable power supply generates a usage period of at least eight hours for the remotely controlled device.

[0239] 12. The system according to any one of clauses 1 to 11, wherein the rechargeable power supply is substantially fully charged by charging the rechargeable power supply at a charging station within three seconds or less.

[0240] 13. The system according to any one of clauses 1 to 12, wherein the charging station includes a guiding structure to align the remote control device in a suitable orientation for charging the rechargeable power source.

[0241] 14. The system according to any one of clauses 1 to 13 further includes an indicator at the vehicle for indicating the charging status of the rechargeable power source.

[0242] 15. The system according to Clause 14, wherein the indicator indicates the charging status of the rechargeable power supply when it is being charged at a charging station and during use of the remote control device.

[0243] 16. The system according to Clause 14 or Clause 15, wherein the indicator comprises a series of lights, each light representing the level of the charge state of the rechargeable power source.

[0244] 17. The system according to any one of clauses 1 to 16, wherein the remote control device includes a fixing structure for securing the remote control device to one or more fingers of the operator's hand.

[0245] 18. The system according to any one of clauses 1 to 17, wherein the remote control device includes at least one charging contact engaging at least one corresponding charging element on the charging station.

[0246] 19. The system according to Clause 18, wherein the at least one charging contact is recessed from the outer surface of the remote control device.

[0247] 20. The system according to Clause 18 or Clause 19, wherein at least one of the remote control device or charging station includes a switch for detecting whether the at least one charging contact is properly engaged with the at least one corresponding charging element for charging a rechargeable power source, wherein if proper engagement is detected, the charging station enables power delivery to the rechargeable power source, and if proper engagement is not detected, the charging station does not enable power delivery to the rechargeable power source.

[0248] 21. The system according to Clause 20, wherein the remote control device and the charging station are configured such that, before the at least one charging contact is disengaged from the at least one corresponding charging element, the switch instructs the remote control device to be removed from the charging station, thereby stopping the transfer of power from the charging station to the rechargeable power source before the at least one charging contact is disengaged from the at least one corresponding charging element.

[0249] 22. The system according to any one of clauses 1 to 21, wherein the remote control device includes at least two charging contacts positioned to engage corresponding charging elements on a charging station.

[0250] 23. The system according to any one of clauses 1 to 22, wherein if no vehicle-related activity occurs within a first predetermined time period after the establishment of communication between the remote control device and the controller, then the communication between the remote control device and the controller terminates and the controller must be re-established to fulfill the wireless request from the remote control device.

[0251] 24. The system according to Clause 23, wherein if no vehicle-related activity occurs within a second predetermined time period after the establishment of communication between the remote control device and the controller, and the second predetermined time period is less than the first predetermined time period, then the communication between the remote control device and the controller is terminated, but can be re-established by performing an acknowledgment method using the remote control device.

[0252] 25. The system according to Clause 24, wherein the confirmation method includes executing a sequence of buttons on a remote control device.

[0253] 26. The system according to any one of clauses 1 to 25, wherein the charging station is implemented in the driving controls of the vehicle, and the rechargeable power source is charged by an operator holding the driving controls.

[0254] 27. The system according to any one of clauses 1 to 26, wherein if the sensed temperature is determined to be higher than a predetermined setpoint temperature, then the rechargeable power supply is discharged to a high-temperature charging state.

[0255] 28. The system described in Clause 27, wherein the sensed temperature is the ambient temperature.

[0256] 29. The system described in Clause 27 or Clause 28, wherein the sensed temperature is the temperature of the rechargeable power supply.

[0257] 30. The system according to any one of clauses 1 to 29, wherein if the sensed temperature is determined to be above a predetermined threshold temperature, then the rechargeable power supply is charged at the charging station to a predetermined charging level below 100% charging level.

[0258] 31. The system according to any one of clauses 1 to 30, wherein the request sent by the remote control device includes a driving request for the vehicle to move forward across the floor surface.

[0259] 32. The system according to any one of clauses 1 to 31, wherein the charging station is located on the side of the vehicle.

[0260] 33. The system according to any one of clauses 1 to 32, wherein the charging station is located near the steering wheel.

[0261] 34. The system according to any one of clauses 1 to 33, wherein the wireless transmitter enters a low-power mode when the rechargeable power supply of the remote control device is being charged at a charging station.

[0262] 35. A kit for retrofitting a material handling vehicle, the vehicle including a controller that responds to communication from an associated remote control device used by an operator interacting with the vehicle, the kit comprising:

[0263] The charging station at the vehicle location is used to charge the rechargeable power source of the remotely controlled equipment; and

[0264] The charging station is electrically coupled to the vehicle's power supply.

[0265] 36. The kit as described in Clause 35 further includes a pairing system for establishing communication between the remote control device and the controller, such that the controller will respond to wireless requests from the remote control device.

[0266] 37. The kit as described in Clause 36, wherein communication between the remote control device and the controller is established concurrently during charging of the rechargeable power supply at the charging station.

[0267] 38. The kit as described in Clause 36 or Clause 37, wherein communication between the remote control device and the controller, and charging of the rechargeable power supply at the charging station, are initiated with a single action.

[0268] 39. The kit as described in Clause 38, wherein a single action includes making a component of the remote control device physically contact an element of the charging station.

[0269] 40. The kit described in any of clauses 36 to 39 further includes a pairing indicator that confirms the establishment of communication between the remote control device and the controller.

[0270] 41. The kit according to any one of clauses 36 to 40, wherein the time period for establishing communication between the remote control device and the controller is less than or equal to the pairing time period.

[0271] 42. The kit according to any one of clauses 35 to 41, wherein the rechargeable power supply is substantially fully charged by charging the rechargeable power supply at a charging station for five seconds or less.

[0272] 43. The kit as described in Clause 42, wherein the basic fully charged state of the rechargeable power supply generates a usage period of at least two hours for the remotely controlled device.

[0273] 44. The kit as described in Clause 42 or Clause 43, wherein the basic fully charged state of the rechargeable power supply generates a usage period of at least eight hours for the remotely controlled device.

[0274] 45. The kit according to any one of clauses 35 to 44, wherein the rechargeable power supply is substantially fully charged by charging the rechargeable power supply at a charging station for three seconds or less.

[0275] 46. ​​The kit according to any one of clauses 35 to 45, wherein the charging station includes a guiding structure to align the remote control device in the appropriate orientation for charging the rechargeable power source.

[0276] 47. The kit according to any one of clauses 35 to 46 further includes an indicator at the vehicle for indicating the charging status of the rechargeable power source.

[0277] 48. The kit as described in Clause 47, wherein the indicator indicates the charging status of the rechargeable power supply when it is being charged at a charging station and during use of the remote control device.

[0278] 49. The kit as described in Clause 47 or Clause 48, wherein the indicator comprises a series of lights, each light representing the level of the rechargeable power supply's charge status.

[0279] 50. The kit according to any one of clauses 35 to 49, wherein the remote control device includes at least one charging contact engaging at least one corresponding charging element on the charging station.

[0280] 51. The kit according to Clause 50, wherein at least one of the remote control device or charging station includes a switch for detecting whether the at least one charging contact is properly engaged with the at least one corresponding charging element for charging the rechargeable power source, wherein if proper engagement is detected, then the charging station enables power delivery to the rechargeable power source, and if proper engagement is not detected, then the charging station does not enable power delivery to the rechargeable power source.

[0281] 52. The kit according to Clause 51, wherein the remote control device and the charging station are configured such that, prior to the at least one charging contact being disengaged from the at least one corresponding charging element, the switch instructs the remote control device to be removed from the charging station, thereby stopping the transfer of power from the charging station to the rechargeable power source prior to the at least one charging contact being disengaged from the at least one corresponding charging element.

[0282] 53. The kit according to any one of clauses 35 to 52, wherein the remote control device includes at least two charging contacts positioned to engage corresponding charging elements on a charging station.

[0283] 54. The kit according to any one of clauses 35 to 53, wherein the charging station is implemented in the vehicle's driving controls and the rechargeable power source is charged by an operator holding the driving controls.

[0284] 55. The kit according to any one of clauses 35 to 54, wherein if the sensed temperature is determined to be above a predetermined threshold temperature, the rechargeable power supply is charged at the charging station to a predetermined charging level below 100% charge level.

[0285] 56. The kit as described in Clause 55, wherein the sensed temperature is the ambient temperature.

[0286] 57. The kit described in any of clauses 35 to 56, wherein the charging station is located on the side of the vehicle.

[0287] 58. A method for charging a remotely controlled device, the remotely controlled device including a wireless transmitter, a rechargeable power supply, and at least one control for causing the wireless transmitter to wirelessly transmit a request to a controller of a material handling vehicle, the method comprising:

[0288] The contact between the components of the remote control device and the elements of the charging station is initiated at the vehicle.

[0289] Sensing the contact between remote control device components and charging station elements;

[0290] Upon sensing a contact, power is supplied from the charging station to the rechargeable power source;

[0291] Disrupts the contact between remote control equipment components and charging station elements;

[0292] Disruption of contact between the sensing remote control device components and the charging station elements; and

[0293] Upon detecting an interruption, it stops supplying power from the charging station to the rechargeable power source.

[0294] 59. The method described in Clause 58, wherein the rechargeable power source is a supercapacitor.

[0295] 60. The method according to Clause 58 or Clause 59 further includes establishing communication between the remote control device and the controller when the remote control device component comes into contact with the charging station component, such that the controller will fulfill a wireless request from the remote control device.

[0296] 61. The method according to Clause 60, wherein the communication between the remote control device and the controller is currently established during the charging of the rechargeable power supply at the charging station.

[0297] 62. The method according to Clause 60 or Clause 61, wherein communication between the remote control device and the controller occurs during the pairing period, and the rechargeable power supply is charged to substantially full charge at the charging station during the charging period, wherein the pairing period overlaps with the charging period.

[0298] 63. The method according to Clause 62, wherein the pairing period is less than or equal to the charging period.

[0299] 64. The method according to any one of clauses 60 to 63 further includes using at least one of auditory or visual queues to confirm the establishment of communication between the remote control device and the controller.

[0300] 65. The method according to any one of clauses 58 to 64, wherein the rechargeable power supply is substantially fully charged by charging the rechargeable power supply at a charging station for a period of five seconds or less.

[0301] 66. The method according to Clause 65, wherein the essentially fully charged state of the rechargeable power supply generates a usage period of at least two hours for the remotely controlled device.

[0302] 67. The method according to Clause 65 or Clause 66, wherein the essentially fully charged state of the rechargeable power supply generates a usage period of at least eight hours for the remotely controlled device.

[0303] 68. The method according to any one of clauses 58 to 67, wherein the rechargeable power supply is substantially fully charged by charging the rechargeable power supply at a charging station for three seconds or less.

[0304] 69. The method according to any one of clauses 58 to 68 further includes displaying the charging status of the rechargeable power source at the vehicle.

[0305] 70. The method according to Clause 69, wherein the charging status of the rechargeable power supply is displayed at the vehicle when the rechargeable power supply is being charged and during use of the remote control device.

[0306] 71. The method according to Clause 69 or Clause 70, wherein the charging status of the rechargeable power supply is displayed via a series of lights, each light representing the level of the charging status of the rechargeable power supply.

[0307] 72. The method according to any one of clauses 58 to 71, wherein the contact between the component of the remote control device and the element of the charging station includes the contact between at least one charging contact of the remote control device and at least one corresponding charging element on the charging station.

[0308] 73. The method according to any one of clauses 58 to 72, wherein if no vehicle-related activity occurs within a first predetermined time period after the establishment of communication between the remote control device and the controller, then the communication between the remote control device and the controller is terminated and the controller must be re-established to fulfill the wireless request from the remote control device.

[0309] 74. The method according to Clause 73, wherein if no vehicle-related activity occurs within a second predetermined time period after the establishment of communication between the remote control device and the controller, and the second predetermined time period is less than the first predetermined time period, then the communication between the remote control device and the controller is terminated, but can be re-established by performing an acknowledgment method using the remote control device.

[0310] 75. The method of claim 74, wherein the confirmation method comprises executing a sequence of buttons on the remote control device.

[0311] 76. The method according to any one of clauses 58 to 75, wherein the charging station is implemented in the driving controls of the vehicle, and the rechargeable power source is charged by an operator holding the driving controls.

[0312] 77. The method according to any one of clauses 58 to 76 further includes discharging the rechargeable power supply to a high-temperature charging state if the sensed temperature is determined to be higher than a predetermined setpoint temperature.

[0313] 78. The method described in accordance with Clause 77, wherein the sensed temperature is the ambient temperature.

[0314] 79. The method described in accordance with Clause 77 or Clause 78, wherein the sensed temperature is the temperature of the rechargeable power supply.

[0315] 80. The method according to any one of clauses 58 to 79, wherein if the sensed temperature is determined to be above a predetermined threshold temperature, then the rechargeable power supply is charged at the charging station to a predetermined charging level below 100% charging level.

[0316] 81. The method according to any one of clauses 58 to 80, wherein the charging station is located on the side of the vehicle.

[0317] 82. A system according to any one of clauses 1 to 34, wherein when the operator is positioned on the vehicle, one or more components of the remote control device are turned off or the power supplied to them is reduced.

[0318] 83. A system comprising:

[0319] Material handling vehicles;

[0320] Remote control devices, including:

[0321] Wireless communication systems, including wireless transmitters; and

[0322] Rechargeable power supply;

[0323] The receiver at the vehicle is used to receive transmissions from the wireless transmitter;

[0324] A controller at the vehicle location, communicatively coupled to a receiver, which responds to the reception of transmissions from a remote control device; and

[0325] The charging station at the vehicle location is used to charge the rechargeable power source for remotely controlled devices.

[0326] 84. A kit for retrofitting a material handling vehicle, the vehicle including a controller that responds to communications from an associated remote control device, the remote control device including a wireless communication system including a wireless transmitter and used by an operator interacting with the vehicle, the kit comprising:

[0327] A charging station for a vehicle, configured to be electrically coupled to the vehicle's power supply for charging a rechargeable power source for remote control devices.

[0328] 85. A method for charging a remotely controlled device, the remotely controlled device including a wireless communication system comprising a wireless transmitter and a rechargeable power supply, the method comprising:

[0329] The contact between the components of the remote control device and the elements of the charging station is initiated at the vehicle.

[0330] Sensing the contact between remote control device components and charging station elements;

[0331] Upon sensing a contact, power is supplied from the charging station to the rechargeable power source;

[0332] Disrupts the contact between remote control equipment components and charging station elements;

[0333] Disruption of contact between the sensing remote control device components and the charging station elements; and

[0334] Upon detecting an interruption, it stops supplying power from the charging station to the rechargeable power source.

[0335] 86. The system described in Clause 83, the kit described in Clause 84, or the method described in Clause 85, wherein the rechargeable power source is a supercapacitor.

[0336] 87. The system described in Clause 83 or Clause 86, or the kit described in Clause 84 or Clause 86, further includes a pairing system for establishing communication between the remote control device and the vehicle; or

[0337] The method described under Clause 85 or Clause 86 also includes establishing communication between the remote control device and the vehicle via a pairing system.

[0338] 88. The system as described in Clause 87, wherein communication between the remote control device and the vehicle is established concurrently during charging of the rechargeable power source at the charging station; or

[0339] According to the kit described in Clause 87, the pairing system is configured to concurrently establish communication between the remote control device and the vehicle during charging of the rechargeable power source at the charging station; or

[0340] The method described under Clause 87 also includes establishing communication concurrently between the remote control device and the vehicle during the supply of power from the charging station to the rechargeable power source.

[0341] 89. A system pursuant to Clause 87 or Clause 88, wherein communication between the remote control device and the vehicle, and charging of the rechargeable power source at the charging station, are initiated with a single action; or

[0342] According to the kit described in Clause 87 or Clause 88, the pairing system and charging station are configured such that communication between the remote control device and the vehicle, and charging of the rechargeable power source at the charging station, are initiated with a single action; or

[0343] The methods described under Clause 87 or Clause 88 also include initiating communication between the remote control device and the vehicle with a single action, as well as charging of the rechargeable power source at a charging station.

[0344] 90. A system or kit as described in Clause 89, wherein a single action includes making a component of the remote control device physically contact an element of the charging station; or

[0345] The method described in Clause 89 includes a single action involving making a remote control device component physically contact a charging station element.

[0346] 91. The system or kit described in any one of clauses 87 to 90 further includes a pairing indicator that confirms the establishment of communication between the remote control device and the vehicle; or

[0347] The method described according to any one of Clauses 87 to 90 further includes confirming the establishment of communication between the remote control device and the vehicle via a pairing indicator.

[0348] 92. A system or kit according to any one of clauses 87 to 91, wherein if no vehicle-related activity occurs within a first predetermined time period after communication between the remote control device and the vehicle is established, then the communication between the remote control device and the vehicle is terminated and must be re-established using a pairing system; or

[0349] The method according to any one of Clauses 87 to 91 further includes: if no vehicle-related activity occurs within a first predetermined time period after communication between the remote control device and the vehicle is established, then the communication between the remote control device and the vehicle is terminated, wherein the communication must be re-established using a pairing system.

[0350] 93. A system or kit as described in Clause 92, wherein if no vehicle-related activity occurs within a second predetermined time period after communication between the remote control device and the vehicle is established, and the second predetermined time period is equal to or less than a first predetermined time period, then the communication between the remote control device and the vehicle is terminated, but can be re-established by performing an acknowledgment method using the remote control device without requiring a pairing system; or

[0351] The method according to Clause 92 further includes: if no vehicle-related activity occurs within a second predetermined time period after communication between the remote control device and the vehicle is established, and the second predetermined time period is equal to or less than a first predetermined time period, then the communication between the remote control device and the vehicle is terminated, wherein communication can be re-established by performing an acknowledgment method using the remote control device without requiring a pairing system.

[0352] 94. The system, kit, or method described in Clause 93, wherein the verification method includes executing a sequence of buttons on a remote control device.

[0353] 95. The system described in any one of Clauses 83 or 86 to 94, the kit described in any one of Clauses 84 or 86 to 94, or the method described in any one of Clauses 85 to 94, wherein the basic fully charged state of the rechargeable power supply is achieved by charging the rechargeable power supply at a charging station for a period of five seconds or less, and wherein the basic fully charged state of the rechargeable power supply generates a usage period of at least two hours for the remotely controlled device.

[0354] 96. The system according to any one of clauses 83 or 86 to 95 further includes an indicator at the vehicle for indicating the charging status of the rechargeable power supply, wherein the indicator indicates the charging status of the rechargeable power supply when the rechargeable power supply is being charged at a charging station and during use of the remote control device.

[0355] The kit according to any one of clauses 84 or 86 to 95 also includes an indicator for the vehicle for indicating the charging status of the rechargeable power supply, wherein the indicator is configured to indicate the charging status of the rechargeable power supply when charging the rechargeable power supply at a charging station and during use of the remote control device; or

[0356] The method according to any one of clauses 85 to 95 further includes indicating the charging status of the rechargeable power supply by means of an indicator both when the rechargeable power supply is being charged at a charging station and during use of the remote control device.

[0357] 97. The system according to any one of clauses 83 or 86 to 96, or the method according to any one of clauses 85 to 96, wherein the remote control device includes at least one charging contact that engages at least one corresponding charging element on a charging station; or

[0358] According to any one of Clauses 84 or 86 to 96, the kit includes at least one charging element configured to engage with at least one corresponding charging contact of a remote control device.

[0359] 98. A system or kit according to Clause 97, wherein at least one of the remote control device or charging station includes a presence contact for detecting whether the at least one charging contact is properly engaged with the at least one corresponding charging element for charging a rechargeable power source, wherein if proper engagement is detected, then the charging station enables power delivery to the rechargeable power source, and if proper engagement is not detected, then the charging station does not enable power delivery to the rechargeable power source; or

[0360] The method according to Clause 97 further includes detecting whether the at least one charging contact is properly engaged with the at least one corresponding charging element for charging the rechargeable power source by means of a contact, and if proper engagement is detected, then power supply from the charging station to the rechargeable power source is enabled, and if proper engagement is not detected, then power supply from the charging station to the rechargeable power source is disabled.

[0361] 99. The system according to Clause 98, wherein the arrangement of the remote control device and the charging station is configured such that, prior to the disengagement of at least one charging contact from the at least one corresponding charging element, a contact indicates the removal of the remote control device from the charging station, which stops the power transfer from the charging station to the rechargeable power source, such that the power transfer from the charging station to the rechargeable power source is stopped before the disengagement of at least one charging contact from the at least one corresponding charging element; or

[0362] According to the kit described in Clause 98, a contact is configured to instruct the remote control device to be removed from the charging station before the at least one charging contact is disconnected from the at least one corresponding charging element, which stops the power transfer from the charging station to the rechargeable power source, such that the power transfer from the charging station to the rechargeable power source is stopped before the at least one charging contact is disconnected from the at least one corresponding charging element; or

[0363] The method according to Clause 98 further includes stopping the power transfer from the charging station to the rechargeable power source by indicating the removal of the remote control device from the charging station before the at least one charging contact is disconnected from the at least one corresponding charging element, thereby stopping the power supply from the charging station to the rechargeable power source before the at least one charging contact is disconnected from the at least one corresponding charging element.

[0364] 100. A system according to any one of clauses 83 or 86 to 99, or a kit according to any one of clauses 84 or 86 to 99, wherein if the sensed temperature is determined to be higher than a predetermined setpoint temperature, then the rechargeable power supply is discharged to a high-temperature charging state, wherein the sensed temperature is (i) ambient temperature, or (ii) the temperature of the rechargeable power supply; or

[0365] The method according to any one of clauses 85 to 99 further includes discharging the rechargeable power supply to a high-temperature charging state if the sensed temperature is determined to be higher than a predetermined setpoint temperature, wherein the sensed temperature is (i) the ambient temperature or (ii) the temperature of the rechargeable power supply.

[0366] 101. The system according to any one of clauses 83 or 86 to 100, wherein if the sensed temperature is determined to be above a predetermined threshold temperature, the rechargeable power supply is charged at a charging station to a predetermined charge level below 100% charge level; or

[0367] According to any of the provisions 84 or 86 to 100, the kit wherein if the sensed temperature is determined to be above a predetermined threshold temperature, the charging station is configured to charge the rechargeable power supply to a predetermined charging level below 100% charge level; or

[0368] The method according to any one of clauses 85 to 100 further includes, if the sensed temperature is determined to be above a predetermined threshold temperature, then charging the rechargeable power supply at the charging station to a predetermined charging level below 100% charging level.

[0369] 102. The system described in any one of Clauses 83 or 86 to 101, or the method described in any one of Clauses 85 to 101, wherein the charging station is located on the side of the vehicle; or

[0370] The kit according to any one of clauses 84 or 86 to 101, wherein the charging station is configured to be located on the side of the vehicle.

[0371] 103. The system described in any one of Clauses 83 or 86 to 102, the kit described in any one of Clauses 84 or 86 to 102, or the method described in any one of Clauses 85 to 102, wherein the wireless communication system enters a low power mode while the rechargeable power supply of the remote control device is being charged at a charging station.

[0372] 104. A system according to any one of Clauses 83 or 86 to 103, or a kit according to any one of Clauses 84 or 86 to 103, wherein one or more components of the remote control device are shut down or the power supplied to them is reduced when the operator is positioned on the vehicle; or

[0373] The method described in any of Clauses 85 to 103 further includes shutting down one or more components of the remote control device or reducing the power supplied to it when the operator is positioned on the vehicle.

[0374] 105. The system described in any one of Clauses 83 or 86 to 104, or the kit described in any one of Clauses 84 or 86 to 104, wherein:

[0375] If the voltage of the rechargeable power supply is lower than the voltage threshold before it is charged by the charging station, then the charging station charges the rechargeable power supply at the first power level.

[0376] If the voltage of the rechargeable power source is higher than a voltage threshold before it is charged by the charging station, then the charging station charges the rechargeable power source at a second power level; and

[0377] The first power level is greater than the second power level; or

[0378] The method described according to any one of clauses 85 to 104 further includes:

[0379] If the voltage of the rechargeable power supply is lower than the voltage threshold before it is charged by the charging station, then the rechargeable power supply is charged at the first power level.

[0380] If the voltage of the rechargeable power source is higher than the voltage threshold before being charged at the charging station, then the rechargeable power source is charged at the second power level; and

[0381] The first power level is greater than the second power level.

[0382] 106. The system according to Clause 105, wherein the charging station charges the rechargeable power supply to a substantially fully charged state within approximately the same time frame, regardless of whether the voltage of the rechargeable power supply is higher or lower than a voltage threshold before being charged by the charging station; or

[0383] According to the kit described in Clause 105, the charging station is configured to charge the rechargeable power supply to a substantially fully charged state within approximately the same time frame, regardless of whether the voltage of the rechargeable power supply is higher or lower than a voltage threshold before being charged by the charging station; or

[0384] The method described in Clause 105 also includes charging the rechargeable power supply to a substantially fully charged state within approximately the same time frame, regardless of whether the voltage of the rechargeable power supply is above or below a voltage threshold before being charged by the charging station.

[0385] 107. The system according to any one of clauses 83 or 86 to 106, or the kit according to any one of clauses 84 or 86 to 106, wherein the remote control device includes at least one control communicatively coupled to the wireless communication system, wherein actuation of the control causes the wireless transmitter to wirelessly transmit a request to the vehicle; or

[0386] The method according to any one of clauses 85 to 106, wherein the remote control device includes at least one control communicatively coupled to a wireless communication system, the method further comprising transmitting a request to the vehicle via a wireless transmitter after the control is actuated.

[0387] 108. A system comprising:

[0388] vehicle;

[0389] Remote control devices, including:

[0390] Wireless communication systems, including wireless transmitters; and

[0391] Rechargeable power supply;

[0392] A charging station located at the vehicle, used to charge the rechargeable power source for remotely controlled devices; and

[0393] Sensors are configured to detect contact between components of the remote control device and elements of the charging station.

[0394] The charging station is configured to supply power to the rechargeable power source after detecting contact between the remote control device component and the charging station component, and to stop supplying power to the rechargeable power source from the charging station after the contact between the remote control device component and the charging station component is interrupted.

[0395] It may also optionally include one or more of the system features described in any of Clauses 2 to 34, 82 and / or 84 to 105.

[0396] 109. A method for charging a remotely controlled device using a charging station on a material handling vehicle, the remotely controlled device including a wireless communication system comprising a wireless transmitter and a rechargeable power supply, the method comprising:

[0397] The receiver at the vehicle receives transmissions from the wireless transmitter.

[0398] In response to receiving a transmission from a remote control device via a controller at the vehicle location, the controller can communicatively couple to the receiver; and

[0399] The rechargeable power supply of the remote control device is charged through the charging station at the vehicle location.

[0400] It may also optionally include one or more of the method steps described in any of the provisions of 59-81.

[0401] 110. A kit for modifying a material handling vehicle, the kit comprising:

[0402] A charging station for a vehicle, configured to be electrically coupled to the vehicle's power supply for charging a rechargeable power source for a remote control device.

[0403] It may also optionally include one or more of the suite features described in any of Clauses 36-57.

[0404] 111. A system comprising:

[0405] The kit as described in Clause 108;

[0406] Material handling vehicles;

[0407] Remote control devices, including:

[0408] Wireless communication systems, including wireless transmitters; and

[0409] Rechargeable power supply;

[0410] The receiver at the vehicle is used to receive transmissions from the wireless transmitter; and

[0411] The controller at the vehicle is communicatively coupled to the receiver, which responds to the reception of transmissions from the remote control device;

[0412] It may also optionally include one or more of the system features described in any of Clauses 2 to 34, 82 and / or 84 to 105.

[0413] It should be understood that the optional features described in the systems of Clauses 1 and 83, the suites of Clauses 35 and 84, and the methods of Clauses 58 and 85, as described in Clauses 2 to 34, 36-57, 59-82, and 86 to 107 listed above, are also intended to be used in combination with one or more of the systems of Clauses 106 and / or 109, the methods of Clause 107, and the suites of Clause 108.

[0414] Furthermore, the optional features of the system described in Clause 1, the suite of Clause 35, and the method described in Clause 58 are intended to be combined with one or more of the system of Clause 83, the suite of Clause 84, and the method of Clause 85. Additionally, the optional features of the system described in Clause 83, the suite of Clause 84, and the method described in Clause 85 are intended to be combined with one or more of the system of Clause 1, the suite of Clause 35, and the method of Clause 58.

[0415] The terms “pairing” and “synchronization” (as used herein and in various patents and published patent applications incorporated herein by reference) are used interchangeably to describe a secure process in which the wireless remote control device and the vehicle controller recognize each other as valid command and response devices.

[0416] The invention of this application has been described in such detail and with reference to embodiments thereof. It will be apparent that modifications and variations are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. A method for establishing a wireless connection between a remote control device and a controller on a material handling vehicle, the remote control device including a wireless transmitter, and the material handling vehicle including a receiver for receiving transmissions from the wireless transmitter, the method comprising: Detect the voltage at one or more charging contacts of the remote control device; In response to detecting voltage at the one or more charging contacts, one or more notifications indicating that the remote control device is available to communicate with nearby devices are transmitted via the wireless transmitter of the remote control device; One or more notifications are received at the vehicle by the receiver. In response to receiving one or more notifications sent, the vehicle issues a scan request for a specific remote control device associated with the received notification; The remote control device responds to the scanning request using a unique identifier. The unique identifier is received by the receiver at the vehicle. Verify the unique identifier; as well as In response to verifying the unique identifier, a wireless connection is established between the remote control device and the controller.

2. The method according to claim 1, wherein, Once the wireless connection is established, the vehicle communicates wirelessly with the remote control device, and the controller is able to execute wireless requests received from the remote control device.

3. The method according to claim 1 or 2, wherein, If, before the vehicle issues a scan request for a specific remote control device, it receives one or more notifications from two or more remote control devices via the receiver at the vehicle, the vehicle does not issue a scan request and requests the user to remove the remote control device from the vehicle before the method can be executed again.

4. The method according to claim 1 or 2, further comprising: Before the wireless transmitter sends one or more announcements, the signal strength of the wireless transmission from the wireless transmitter is reduced from a normal level to a reduced level.

5. The method according to claim 4, further comprising: Once the wireless connection between the remote control device and the controller is established, the signal strength of the wireless transmission from the wireless transmitter is restored to normal levels.

6. The method according to claim 3, further comprising: Before the wireless transmitter sends one or more announcements, the signal strength of the wireless transmission from the wireless transmitter is reduced from a normal level to a reduced level.

7. The method according to claim 6, further comprising: Once the wireless connection between the remote control device and the controller is established, the signal strength of the wireless transmission from the wireless transmitter is restored to normal levels.

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