On-Board Charging Station for Remote Control Devices

Abstract

This application relates to an on-board charging station for a remote control device. A system includes a remote control device that can be used by an operator interacting with a material 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 communicatively 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 a patent application for invention with an international filing date of December 18, 2019, application number 201980089595.3, and invention title "On-Board Charging Station for Remote Control Devices". Technical Field

[0002] The present invention relates to an on-board charging station for a remote control device, such as may be used by an operator interacting with a materials handling vehicle. Background Art

[0003] Materials handling vehicles are commonly used for order picking in warehouses and distribution centers. Such vehicles typically include a power unit and a load handling assembly, which may include load-carrying forks. The vehicle also has a control structure for controlling the operation and movement of the vehicle.

[0004] In a typical order picking operation, an operator fills an order from available inventory items located in storage areas provided along one or more aisles of a warehouse or distribution center. The operator drives the vehicle between the respective picking locations of the item(s) to be picked. The operator may drive the vehicle either by using the control structure on the vehicle or via a wireless remote control device associated with the vehicle (such as the remote control device disclosed in co-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 present invention, a system includes a materials handling vehicle and a remote control device that may be used by an operator interacting with the materials handling vehicle. The remote control device includes a wireless communication system including a wireless transmitter and a rechargeable power source. 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 responsive to receiving a transmission from the remote control device; and a charging station at the vehicle for charging the rechargeable power source of the remote control device.

[0006] The rechargeable power source may 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 the remote control device and the vehicle may be established concurrently during charging of the rechargeable power source at the charging station.

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

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

[0011] The time period taken to establish communication between the remote control device and the vehicle can be less than or equal to a pairing period.

[0012] If no vehicle-related activity occurs after a first predetermined amount of time has elapsed since communication was 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 the pairing system. If no vehicle-related activity occurs after a second predetermined amount of time has elapsed since communication was established between the remote control device and the vehicle, the second predetermined amount of time being equal to or less than the first predetermined amount of time, then communication between the remote control device and the vehicle can be terminated, but can be re-established by performing a confirmation method using the remote control device without using the pairing system. The confirmation method can include performing a button sequence on the remote control device.

[0013] A substantially fully charged state of the rechargeable power source can be achieved by charging the rechargeable power source at the charging station in a time of five seconds or less, four seconds or less, or three seconds or less. The substantially fully charged state of the rechargeable power source can result in a usage period of the remote control device of at least two hours or at least eight hours.

[0014] The charging station can include a guiding structure to align the remote control device in a proper orientation for charging the rechargeable power source.

[0015] The system can also include an indicator at the vehicle for indicating the charging state of the rechargeable power source. The indicator can indicate the charging state of the rechargeable power source when the rechargeable power source is being charged at the charging station and during use of the remote control device. The indicator can include a series of lights, each light representing a level of the charging state of the rechargeable power source.

[0016] The remote control device can include a securing 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 the outer surface of the remote control device. At least one of the remote control device or the charging station may include a presence contact that detects whether the at least one charging contact is correctly engaged with the at least one corresponding charging element for charging a rechargeable power source, wherein if correct engagement is detected, then power transfer to the rechargeable power source is enabled by the charging station, and if correct engagement is not detected, then power transfer 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 the presence contact indicates 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, such that power transfer from the charging station to the rechargeable power source is stopped 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 that are positioned to engage corresponding charging elements on a charging station.

[0019] The charging station may be implemented in a vehicle's drive control and may charge a rechargeable power source by an operator gripping the drive control.

[0020] If a sensed temperature is determined to be higher than a predetermined setpoint temperature, then the rechargeable power source may be discharged to a high temperature charging state. The sensed temperature may be an ambient temperature or the temperature of the rechargeable power source.

[0021] If a sensed temperature is determined to be higher than a predetermined threshold temperature, then the rechargeable power source may be charged at the charging station to a predetermined charge level that is less than 100% charge level.

[0022] A request sent by the remote control device may include a drive request to request the vehicle to move forward across a floor surface.

[0023] The charging station may be located at a side of the vehicle or near a steering wheel.

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

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

[0026] If the voltage of a rechargeable power source is below a voltage threshold before being charged by a charging station, the charging station may charge the rechargeable power source at a first power level, and if the voltage of the rechargeable power source is above the voltage threshold before being charged by the charging station, the charging station may charge the rechargeable power source at a second power level. The first power level may 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 may 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] In other aspects of the present invention, there is provided a kit for retrofitting a material handling vehicle that includes a controller responsive to transmissions from an associated remote control device that includes a wireless communication system that includes a wireless transmitter and is used by an operator interacting with the vehicle. The kit includes a charging station at the vehicle configured to be electrically coupled to a vehicle power source of the vehicle for charging a rechargeable power source of the remote control device.

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

[0030] During charging of the rechargeable power source at the charging station, communication between the remote control device and the vehicle may be established concurrently.

[0031] Communication between the remote control device and the vehicle and charging of the rechargeable power source at the charging station may be initiated with a single action. The single action may include physical contact of a component of the remote control device with an element of the charging station.

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

[0033] The time period taken to establish communication between the remote control device and the vehicle may be less than or equal to a pairing period.

[0034] By charging the rechargeable power source at the charging station in five seconds or less, four seconds or less, or three seconds or less, a substantially fully charged state of the rechargeable power source may be achieved. The substantially fully charged state of the rechargeable power source may result in a usage period of the remote control device of at least two hours or at least eight hours.

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

[0036] The kit may also include an indicator at the vehicle for indicating the charging status of the rechargeable power source. The indicator may indicate the charging status of the rechargeable power source when the rechargeable power source is being charged at a charging station and during use of the remote control device. The indicator may include a series of lights, each light representing a level of the charging status of the rechargeable power source.

[0037] The remote control device may include at least one charging contact that engages at least one corresponding charging element on the 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 the rechargeable power source, wherein if proper engagement is detected, then power transfer to the rechargeable power source is enabled by the charging station, and if proper engagement is not detected, then the charging station does not enable power transfer to the rechargeable power source. The arrangement of the remote control device and the charging station may be configured such that the presence contact indicates 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, such that power transfer from the charging station to the rechargeable power source stops 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 that are positioned to engage corresponding charging elements on the charging station.

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

[0039] If the sensed temperature is determined to be higher than a predetermined threshold temperature, then the rechargeable power source may be charged at the charging station to a predetermined charge level that is less than 100% charge level. The sensed temperature may be the ambient temperature.

[0040] The charging station may be located on the side of the vehicle.

[0041] According to other aspects of the present invention, a method for charging a remote control device is provided, the remote control device including a wireless communication system including a wireless transmitter and a rechargeable power source. The method includes: initiating contact between components of the remote control device and elements of a charging station located at the vehicle; sensing the contact between the remote control device components and the charging station elements; after sensing the contact, powering the rechargeable power source from the charging station; interrupting the contact between the remote control device components and the charging station elements; sensing the interruption of the contact between the remote control device components and the charging station elements; and after sensing the interruption, stopping powering the rechargeable power source from the charging station.

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

[0043] The method may further include establishing communication between the remote control device and the vehicle when a component of the remote control device contacts a charging station element.

[0044] During charging of the rechargeable power source at the charging station, communication between the remote control device and the vehicle may be established concurrently.

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

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

[0047] A substantially full charge state of the rechargeable power source may be achieved by charging the rechargeable power source at the charging station within five seconds or less, four seconds or less, or three seconds or less.

[0048] A substantially full charge state of the rechargeable power source may result in a usage period of the remote control device of at least two hours or at least eight hours.

[0049] The method may further include displaying a charging state of the rechargeable power source at the vehicle. The charging state of the rechargeable power source may be displayed at the vehicle when the rechargeable power source is being charged and during use of the remote control device. The charging state of the rechargeable power source may be displayed via a series of lights, each light indicating a level of the charging state of the rechargeable power source.

[0050] Initiating contact between a component of the remote control device and an element of the charging station may include initiating 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 after a first predetermined amount of time has elapsed after communication is established between the remote control device and the vehicle, then communication between the remote control device and the vehicle may be terminated and must be re-established using the pairing system. If no vehicle-related activity occurs within a second predetermined amount of time after communication is established between the remote control device and the vehicle, the second predetermined amount of time being equal to or less than the first predetermined amount of time, then communication between the remote control device and the vehicle may be terminated, but may be re-established by performing a confirmation method using the remote control device. The confirmation method may include performing a button sequence on the remote control device.

[0052] The charging station can be implemented in the vehicle's drive control, and the rechargeable power source can be charged by the operator gripping the drive control.

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

[0054] If the sensed temperature is determined to be higher than a predetermined threshold temperature, the rechargeable power source can be charged at the charging station to a predetermined charge level that is less than 100% charge level.

[0055] The charging station can be located on the side of the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 and Figure 2 are side and top views of a material handling vehicle capable of remote wireless operation in accordance with various aspects of the present invention;

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

[0058] Figure 3 is a schematic illustration of several components of a material handling vehicle capable of remote wireless operation in accordance with various aspects of the present invention;

[0059] Figures 4 - 7 is a view of a remote control device in accordance with various aspects of the present invention;

[0060] Figure 8A and Figure 8B are cross-sectional views showing a remote control device engaged with a charging station in accordance with various aspects of the present invention;

[0061] Figure 9 and Figure 10 is a view of another remote control device in accordance with various aspects of the present invention;

[0062] Figure 11 is a schematic illustration of several components of a charging station in accordance with various aspects of the present invention;

[0063] Figures 12 - 14 is a view showing a remote control device and a charging station in accordance with various aspects of the present invention;

[0064] Figure 15 is a schematic illustration of several components of a remote control device in accordance with various aspects of the present invention;

[0065] Figure 16 depicts a method in accordance with various aspects of the present invention;

[0066] Figure 17 depicts a pairing method according to various aspects of the present invention;

[0067] Figure 18 depicts another pairing method according to various aspects of the present invention;

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

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

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

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

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

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

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

[0075] In the following detailed description of the illustrated embodiments, reference is made to the accompanying drawings, which show, by way of illustration and not limitation, specific embodiments in which the invention may be practiced. 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 - level picking truck

[0077] Now referring to the drawings, especially Figure 1 and Figure 2, the 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 aspects of the present 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 instead of the illustrated arrangement of the forks 16, the load handling assembly 12 may include other load handling features, such as a load backrest, scissor lift forks, outrigger brackets, or individually height-adjustable forks, to name just a few examples. Further, the load handling assembly 12 may include load handling features, such as a mast, a load platform, a collection cage, or other support structures carried by or otherwise provided for handling the load supported and carried by the vehicle 10. Although the present disclosure is made with reference to the illustrated vehicle 10, it will be apparent to those skilled in the art that the vehicle 10 may include a variety of other industrial vehicles, such as forklifts, reach trucks, etc., and the following description of the present invention with reference to the drawings should not be limited to order picking trucks unless otherwise specified. Additionally, the vehicle 10 may be implemented in other forms, styles, and features, including vehicles 10 that do not include a load handling assembly, such as trailers, etc.

[0078] The illustrated power unit 14 includes a stepped operator station 20 that separates a first end section (opposite the forks 16) of the power unit 14 from a second end section (near the forks 16). The operator station 20 includes a platform 21 on which an operator can stand to drive the vehicle 10 and / or provide a location from which the operator can operate the various included features of the vehicle 10.

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

[0080] According to Figure 2 one embodiment shown in, the vehicle 10 may include a pole that extends vertically from the power unit 14 and includes an antenna 30 provided to receive control signals from a corresponding wireless remote control device 32. The pole may include a light 33 at the top, as shown in Figure 1 andFigure 2 as shown in. According to Figure 2A In another embodiment shown in, the antenna may be located within other vehicle components such that control signals from the remote control device 32 are received elsewhere in the vehicle 10, as will be discussed below. The remote control device 32 includes additional components of the system 8 that will be described in more detail below.

[0081] The remote control device 32 may be manually operated by an operator, for example, by pressing a button or other control, to cause the remote control device 32 to transmit at least a first type of signal specifying a driving request to the vehicle 10 paired with the remote control device 32. The driving request is a command to request the vehicle 10 to drive, as will be described in more detail herein. Although the remote control device 32 is in Figure 1 and Figure 2is shown as a finger-mounted structure in the figure, but various implementations of the remote control device 32 can be achieved, including, for example, a glove structure, a lanyard, or a belt-mounted structure, etc. Further, the vehicle 10 and the remote control device 32 can 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 on September 14, 2006, titled "SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE"; U.S. Patent Application Serial No. 11 / 855,310, filed on September 14, 2007, titled "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, filed on September 14, 2007, titled "SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE", now U.S. Patent No. 8,072,309; U.S. Provisional Patent Application Serial No. 61 / 222,632, filed on July 2, 2009, titled "APPARATUS FOR REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE"; U.S. Patent Application Serial No. 12 / 631,007, filed on December 4, 2009, titled "MULTIPLE ZONE SENSING FOR MATERIALS HANDLING VEHICLES", now U.S. Patent No. 9,645,968; U.S. Provisional Patent Application Serial No. 61 / 119,952, filed on December 4, 2008, titled "MULTIPLE ZONE SENSING FOR REMOTELY CONTROLLED MATERIALS HANDLING VEHICLES"; and / or U.S. Patent No. 7,017,689, titled "ELECTRICAL STEERING ASSIST FOR MATERIAL HANDLING VEHICLE", issued on March 28, 2006. The entire disclosure of each document is incorporated herein by reference. Additional details related to the remote control device 32 will be discussed in detail below.

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

[0083] The obstacle sensor 40 may include any suitable proximity detection technology, such as ultrasonic sensors, image capture devices, infrared sensors, laser scanner sensors, etc., which are capable of detecting the presence of an object / obstacle or generating signals that can be analyzed to detect the presence of an object / obstacle in a predefined detection zone(s). In the Figure 1 and Figure 2 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 spaced apart from the second obstacle detectors 44A and 44B along the vertical axis V of the vehicle 10 that defines a vertical direction, i.e., the second obstacle detectors 44A and 44B are located below the first obstacle detector 42 (closer to the ground than the first obstacle detector 42), see A . The second obstacle detectors 44A and 44B are spaced apart from each other along the horizontal axis H of the vehicle 10 that defines a horizontal direction, see Figure 1 . A See Figure 2 .

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

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

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

[0087] Figure 1 and Figure 2 As shown in, the vehicle 10 further includes a charging station 50 that 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 - level picking truck

[0089] Reference Figure 3 , the block diagram illustrates a control arrangement for integrating remote control commands with vehicle 10. A receiver 102, which can be, for example, a Bluetooth Low Energy (BLE) radio transceiver, is provided for receiving commands issued by a remote control device 32. The receiver 102 passes the received control signal to a controller 103, which implements an appropriate response to the received command and can thus also be referred to herein as the master controller. In this regard, the controller 103 is implemented in hardware and can also execute software (including firmware, resident software, microcode, etc.). Additionally, aspects of the present invention can take the form of a computer program product implemented in one or more computer-readable media having computer-readable program code embodied thereon. For example, vehicle 10 can include a memory storing the computer program product, which, when implemented by a processor of the controller 103, implements steering correction as more fully described herein.

[0090] Thus, the controller 103 can at least partially define a data processing system adapted to store and / or execute program code and can include, for example, at least one processor directly or indirectly coupled to a memory element via a system bus or other suitable connection. The memory elements can include local memory employed during 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 implemented by the controller 103 in response to a command received wirelessly (e.g., via a wireless transmitter 178 of the remote control device 32, which will be discussed below) and sent to the receiver 102 on the vehicle 10 can include one or more actions or inactions, depending on the logic being implemented. Positive actions can include controlling, adjusting, or otherwise affecting one or more components of the vehicle 10. The controller 103 can also receive information from other inputs 104 (e.g., from sources such as presence sensors 22, obstacle sensors 40, switches, load sensors, encoders, and other devices / features available to the vehicle 10) to determine appropriate actions in response to commands received from the remote control device 32. The sensors 22, 40, etc. can be connected to the controller 103 via the input 104 or via a suitable truck network such as a Controller Area Network (CAN) bus 110.

[0092] In an exemplary arrangement, the remote control device 32 is operable to wirelessly transmit a control signal to a receiver 102 on the vehicle 10, the control signal representing a first type of signal such as a drive command. The drive command is also referred to herein as a "drive signal", "drive request", or "forward signal". The drive request is used to initiate a request to drive the vehicle 10. For example, as long as the drive signal is received by the receiver 102 and / or transmitted by the remote control device 32 for a predetermined amount, e.g., to move the vehicle 10 forward in a first direction or jog a limited driving distance or for a limited time. For example, the first direction may be defined by the vehicle 10 first moving in the power unit 14, i.e., the direction in which the forks 16 move backward. However, other driving directions may alternatively be defined. Also, the vehicle 10 may be controlled to drive in a generally straight direction or along a previously determined course. Accordingly, the limited driving distance may be specified by an approximate driving distance, driving time, or other measurement.

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

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

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

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

[0097] Accordingly, if vehicle 10 is moving in response to a command received from remote control device 32, then controller 103 can dynamically change, control, adjust, or otherwise affect the remote control operation, such as by stopping vehicle 10, changing the steering angle of vehicle 10, or taking other actions. Thus, particular vehicle features, the state / condition of one or more vehicle features, the vehicle environment, etc. can affect the manner in which controller 103 responds to a drive request from remote control device 32.

[0098] The controller 103 may reject confirmation of a received drive request based on, for example, one or more predetermined conditions related to the environment or one or more operating factors. For example, the controller 103 may ignore otherwise valid drive requests based on information obtained from one or more of the sensors 22, 40. By way of illustration, in accordance with various aspects of the present invention, when determining whether to respond to a drive command from the remote control device 32, the controller 103 may optionally consider factors such as whether the operator is on the vehicle 10. As described above, the vehicle 10 may include at least one presence sensor 22 for detecting whether the operator is located on the vehicle 10. In this regard, the controller 103 may also be configured to respond to a drive request to operate the vehicle 10 under remote control when one or more presence sensors 22 specify that no operator is on the vehicle 10. Thus, in this embodiment, the vehicle 10 cannot be operated in response to a wireless command from the remote control device 32 unless the operator physically leaves the vehicle 10. Similarly, if the obstacle sensor 40 detects an object, including the operator, approaching and / or nearing the vehicle 10, then the controller 103 may reject confirmation of the drive request from the remote control device 32. Thus, in an exemplary embodiment, the operator must be located within a restricted range of the vehicle 10, e.g., close enough to the vehicle 10 to be within wireless communication range (which may be limited by setting a maximum distance of the operator from the vehicle 10). Other arrangements may alternatively be implemented.

[0099] Any other reasonable conditions, factors, parameters, or other considerations may alternatively be implemented by the controller 103 to interpret and take actions in response to signals received from the transmitter 178. Other exemplary factors are set forth in more detail in 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; U.S. Provisional Patent Application Serial No. 61 / 222,632, entitled "APPARATUS FOR REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE"; U.S. Patent Application Serial 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 Serial No. 61 / 119,952, entitled "MULTIPLE ZONE SENSING FOR REMOTELY CONTROLLED MATERIALS HANDLING VEHICLES", the disclosures of which are hereby incorporated by reference in their entirety.

[0100] After confirming the driving request, the controller 103 interacts with the traction motor controller 106, for example, directly or indirectly (e.g., via a bus such as the CAN bus 110 if used), to propel the vehicle 10. Depending on the specific implementation, the controller 103 may interact with the traction motor controller 106 and an optional steering controller 112 to propel the vehicle 10 as long as a driving control signal is received. Alternatively, the controller 103 may interact with the traction motor controller 106 and optionally the steering controller 112 to advance the vehicle 10 for a period of time or a predetermined distance in response to the detection and maintained actuation of driving control on the remote control device 32. Further, the controller 103 may be configured to "time out" and stop the vehicle 10 based on a predetermined event (such as exceeding a predetermined time period or driving distance), regardless of the detected and maintained actuation of the corresponding control on the 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 the vehicle 10 should brake and / or otherwise come to rest). The second type of signal may also be implicit, for example, after implementing a "drive" command, e.g., after the vehicle 10 has traveled a predetermined distance, traveled for a predetermined time, etc., under remote control in response to the drive command. If the controller 103 determines that the wirelessly received signal is a stop signal, then the controller 103 sends a signal to the traction motor controller 106, the brake controller 116, and / or other truck components to bring the vehicle 10 to rest. As an alternative to the stop signal, the second type of signal may include a "coast signal" or a "controlled deceleration signal" specifying that the vehicle 10 should coast and ultimately decelerate to a stop.

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

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

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

[0105] In Figure 3 the charging station 50, the receiver 102, and the pairing system 34 are depicted as different functional blocks. However, those of ordinary skill in the art will recognize that two or more of these components can be combined in a single element to provide a multi-functional 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 turn.

[0108] Referring Figure 4 - Figure 8, 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 device, etc. The remote control device 32 can be mountable on one finger, two fingers, or more than two fingers of the operator.

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

[0110] The rechargeable power source 180 can be a supercapacitor, a high-capacity battery, etc. For example, an AVX supercapacitor, model SCCR20E335PRB, can be used, which has a rated voltage of 3V and a capacitance of 3.3F. The rechargeable power source 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 may be preferred to correspond to an eight-hour work shift of an operator.

[0111] A supercapacitor (also known as a supercap or ultracapacitor) is a high-capacity capacitor with a capacitance value much higher than that of other capacitors, but typically with a lower voltage limit, to bridge the gap between electrolytic capacitors and rechargeable batteries. They usually 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. Since supercapacitors can be used in applications that require many rapid charge / discharge cycles, some embodiments of the remote control device 32 can include a supercapacitor as the rechargeable power source 180. In an embodiment of the present invention, the current supplied to the supercapacitor can be limited to approximately 2 A and the charging to full charge can be completed in approximately 2 seconds or less. Regardless of the specific type of rechargeable power source 180 used, embodiments of the present invention contemplate recharging the rechargeable power source 180 to a desired amount (such as a full charge state, or a charge state below substantially full charge) via the charging station 50 within a 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 charge, and / or the desired charging period, as will be discussed in more detail herein.

[0112] Reference Figure 6 , the remote control device 32 further includes a securing structure 188 for securing the remote control device 32 to one or more fingers of an operator's hand. Figure 6 The securing structure 188 in the embodiment shown in includes a retaining strap 190 that 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 an operator. The remote control device 32 is provided with first and second slots 192A and 192B at opposite ends of the remote control device 32 for receiving the retaining strap 190.

[0113] Figure 6 The retaining strap 190 shown in 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 2) Right - 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 retention strap 190. In one exemplary embodiment, the first end 190A of the retention strap 190 passes through the first slot 192A and the second end 190B of the retention strap 190 passes through the second slot 192B. The first end 190A of the retention strap 190 can be permanently fastened to the rigid base 172, for example, via stitching or gluing, while the second end 190B of the retention strap 190 can be releasably inserted through the second slot 192B and folded back such that the hook - and - loop fasteners 191 engage each other to fasten the retention strap 190 to the operator's finger. The retention strap 190 can be adjusted to accommodate different finger sizes or such that the remote control device 32 can be worn over a glove (not shown). Note that other types of retention straps 190 can be used.

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

[0115] The remote control device 32 is compact, and substantially the entire remote control device 32 can be mounted and positioned directly above the operator's index finger. Thus, the interference caused by the operator wearing the remote control device 32 while performing work tasks is minimal or non - existent. Since the rigid base 172 and the upper housing 174 are preferably formed from 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 the upper housing 174 define a durable, generally non - flexible, and rigid structure.

[0116] The operator can easily manually actuated the drive button 197A with his / her thumb to cause the wireless transmitter 178 to wirelessly transmit at least a first type of signal specifying a drive request or command to the vehicle 10. It is contemplated that as long as the operator holds down the drive button 197A, the drive request can cause the vehicle 10 to drive, either for 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] As Figure 4 and Figure 5 shown, the remote control device 32 also includes one or more charging contacts 210. It should be noted that more or fewer than the four charging contacts 210 shown can be used. For example, one charging contact 210 or two or more charging contacts 210 can be used. In addition, the remote control device 32 also includes one or more sensors in the form of a first presence contact 212, which is illustrated in Figure 4 and Figure 5 as a single first presence contact 212 located in the middle of the 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 within the opening 214, which can prevent 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 the (one or more) first presence contacts 212 can be used without departing from the scope and spirit of the present invention.

[0118] In an embodiment, the charging contacts 210 mate or engage with elements (e.g., the electrical contacts or charging elements 220 of the in-vehicle charging station 50, which will be discussed below), and the first presence contact 212 mates or engages with a complementary second sensor in the form of a second presence contact 222, such as a switch, spring pin, or pressure pin of the in-vehicle charging station 50, as Figure 8A and Figure 8B shown and will be described in more detail herein. It should be noted that one or more of the charging contacts 210 and the corresponding charging elements 220 can be provided for redundancy. In one example, Figures 4 - 7 the four charging contacts 210 shown in Figures 12 - 14 and the four charging elements 220 shown in

[0119] Embodiments of the present invention also contemplate contactless or inductive charging, where the rechargeable power supply 180 of the remote control device 32 can be charged by the remote control device 32 being near or on the surface of a compatible inductive charging station (not shown). Such an inductive charging station can 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, where the same reference numerals correspond to components similar to those listed above for Figure 4 -FIG. 8. The remote control device 32 according to this embodiment is intended to be a two-finger design, i.e., Figure 9 and Figure 10 the fixed structure 188 in the embodiment shown in includes a retaining strap 190 that defines first and second finger receiving regions 194, 195 for receiving the index finger and middle finger of an operator using the remote control device 32. According to 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 -FIG. 8. Figure 9 and Figure 10 The remaining components of the remote control device 32 of and can generally be the same as those of the remote control device 32 of Figure 4 -FIG. 8 and will not be described in detail herein.

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

[0122] It should be noted that the first and second presence contacts 212, 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 presence contact 222 and the charging element 220 is such that when the charging process is initiated, the charging contacts 210 of the remote control device 32 and the charging elements 220 of the charging station 50 contact each other before the second presence contact 222 engages the first presence contact 212, see Figure 8A, which shows that the height of the second presence contact 222 is less than the height of the charging element 220, where the height is measured relative to the top surfaces of the respective charging element 220 and the second presence contact housing 222A from which the second presence contact 222 extends. Power supply from the charging station 50 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 the charging element 220 of the charging station 50, and the second presence contact 222 engages the first presence contact 212, enabling power supply from the charging station 50 to the remote control device 32 via the charging element / charging contact 220 / 210, see Figure 8B . After the rechargeable power supply 180 is charged to a desired amount, such as fully charged or charged to a desired amount less than fully charged as described herein, 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. In the case where 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 rechargeable power supply 180 of the remote control device 32 via the charging element / charging contact 220 / 210 is cut off. This arrangement is intended to prevent arcing between the charging element 220 and the charging contact 210. The use of the first presence contact 212 and the second presence contact 222 in the form of spring pins provides the following advantages: precise control of the relative height of the second presence contact 222 with respect to the charging element 220; a small footprint, good sealing, e.g., to prevent moisture from entering the second presence contact housing 222A around the second presence contact 222; and it allows discrimination of the first presence contact 212 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 contacts 212, 222 for initiating the power supply from the charging station 50 to the remote control device 32, there may be a separate switch that the operator engages to start the charging operation. In one specific embodiment using inductive charging, such a switch can be incorporated into the steering control of the vehicle such that the operator's grip on the steering control is detected and charging is subsequently enabled.

[0125] The control 414 for providing a control signal 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 source 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) the remote control device 32 is physically connected to the charging station 50, b) there is a remote control device 32 currently paired with the vehicle's controller 103, c) the progress / status of the current charging operation, and / or d) the charging status of the rechargeable power source 180. The 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, since the pairing and charging processes are performed very quickly, the LED 404 may not display the progress / 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, where the charging profile can be evaluated by the controller 103, for example, to determine whether proper charging of the rechargeable power source 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 the vehicle 10 are illustrated. The charging station 50 can include one or more physical protrusions or guiding structures 420 that help guide the remote control device 32 into proper alignment such that the charging element 220 of the station is aligned with the charging contact 210 of the remote control device 32, i.e., the (one or more) guiding structures 420 align the remote control device 32 in the correct orientation for charging the rechargeable power source 180. In Figure 12 FIG., a single guiding structure 420 including multiple guiding surfaces is shown. The (one or more) guiding structures 420 can be placed around the location of the charging element 220 and can be shaped or angled such that the remote control device 32 is physically guided into proper alignment when the operator places the remote control device 32 in the charging station.

[0127] In Figure 13In [the above], LED 404 includes a visual indicator 424 which indicates that the remote control device 32 is attached to the charging station 50. The visual indicator 424 may 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 may use the second color or the fully filled first color as a pairing indicator to confirm the establishment of communication between the remote control device 32 and the vehicle 10. In addition, according to an alternative aspect of the present invention, after communication is established between the remote control device 32 and the vehicle 10, the LED 404 may flash, illuminate as a second color, or provide some other visual indication as a clue for the operator to perform an action, 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, contrary to a single indicator that can perform both functions, separate indicators may be used for the purpose of indicating that the remote control device 32 is attached to the charging station 50 and indicating that the remote control device 32 has been paired with the vehicle 10.

[0128] LED 404 may 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, the LED 404 may be used as an indicator to indicate the current charging state of the rechargeable power supply 180 of the remote control device 32. Therefore, the LED 404 may indicate the charging state 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 the operator is using the remote control device 32 to assist in performing a work operation). In an exemplary embodiment, the LED 404 may include a series of lights, each light representing a charging state level of the rechargeable power supply 180.

[0129] In Figure 12 and Figure 14 an exemplary position of the second presence contact 222 within the charging station 50 is shown. It should be noted that Figures 12 - 14 the remote control device 32 shown in Figures 4 - 7 is a single - finger embodiment of

[0130] . It should also be noted that the charging contacts 210 and the first presence contact 212 of the single - finger and double - finger embodiments may be arranged to be mirror images of each other. Thus, the same charging station 50 may be used for instances of single - finger or double - finger remote control devices 32.

[0130] The charging station 50 may be located at various positions on the vehicle 10. Its position should be such that it does not interfere with the normal operation of the vehicle 10, but is accessible and convenient for the operator. In an embodiment, the charging station 50 is located within the operator's station 20 (seeFigure 1 and Figure 2 , where the charging station 50 is located within the operator station 20 but is also accessible from outside the vehicle 10), on the surface of one of the sides of the vehicle 10, or, for inductive charging embodiments, within the steering control of the vehicle 10.

[0131] The charging station 50 may include a voltage regulator (not shown) that converts the power received by the charging station 50 from the vehicle 10 into a regulated direct current (DC) voltage signal selected based on the charging characteristics of the rechargeable power source 180. For example, in an embodiment where the rechargeable power source 180 is the above-described AVX supercapacitor or equivalent device, a 3V DC (1%) power supply voltage may be provided to the 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 present invention. For example, one or more components of the remote control device 32 may be combined in an integrated component, or components may be replaced with alternative components that achieve similar / identical purposes.

[0133] In one embodiment, when one or more charging contacts 210 engage corresponding charging elements 220 of the charging station 50, the rechargeable power source 180 is charged via the charging station 50. In some embodiments, there are at least two charging contacts 210 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, where at least one charging contact 210 in each pair must engage 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 source 180, where if a correct engagement is detected, then the charging station 50 enables the transfer of power to the rechargeable power source 180, and if a correct engagement is not detected, then the charging station 50 does not enable the transfer of power to the rechargeable power source 180.

[0134] In addition, the arrangement of the remote control device 32 and the charging station 50 is configured such that the second presence contact 222 indicates removal of the remote control device 32 from the charging station 50, which stops the transfer of power from the charging station 50 to the rechargeable power supply 180 before at least one charging contact 210 is disengaged from at least one corresponding charging element 220. Thus, the transfer of power from the charging station 50 to the rechargeable power supply 180 is stopped before at least one charging contact 210 is disengaged from at least one corresponding charging element 220. For example, this can be achieved by setting the heights of the charging element 220 and the second presence contact 222, as Figure 8A shown, where when the remote control device 32 is inserted into the charging station 50, the charging element 220 is pushed downward into the corresponding element housing 220A before the second presence contact 222 engages the first presence contact 212.

[0135] Figure 15 is a block-level functional diagram of a portion 450 of the remote control device 32 that is 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 depicted in Figure 15 As described above, the remote control device 32 can include one or more charging contacts 210 configured to engage corresponding charging elements. In some embodiments, the charging element can be the charging element 220 of the charging station 50. In other embodiments, the charging element can be the charging element of an adapter that is 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 an expected operating range. A charge controller and disconnect circuitry 454 may monitor the voltage received from the protection circuitry 452 and monitor the current charge state of the rechargeable power source 180 to determine when to stop charging the rechargeable power source 180. For example, according to one exemplary embodiment, when the charge on the rechargeable power source 180 reaches 3V, the charge controller and disconnect circuitry 454 may operate to stop further charging. The charge controller and disconnect circuitry 454 may include temperature sensing capabilities or be connected to a temperature sensor such that the rechargeable power source 180 may be charged (or discharged) to different charge levels. In some embodiments, if the sensed temperature is determined to be higher than a predetermined set point temperature, then the rechargeable power source 180 is discharged to a high temperature charge state, e.g., below a fully charged state. In one exemplary aspect of the present invention, the sensed temperature is the ambient temperature. In an alternative aspect, the sensed temperature is the battery temperature. In some embodiments, if the sensed temperature is determined to be higher than a predetermined threshold temperature, then the rechargeable power source 180 is charged at the charging station 50 to a predetermined charge level below the 100% charge level. This may help prevent damage or degradation of the rechargeable power source 180.

[0137] As Figure 15 shown, the remote control device 32 may include a wireless communication system 456, such as, for example, a BLE radio transceiver that may communicate via a BLE connection with the BLE radio transceiver 402 of the charging station 50. 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 when the rechargeable power source 180 of the remote control device 32 is being charged at the charging station 50, to ensure that only the remote control device 32 within a minimum distance from 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) is recognized as the remote control device 32 to be paired. Additionally, if the BLE radio transceiver 402 of the charging station 50 is to identify two or more remote control devices 32 that may be used for pairing and cannot determine the correct remote control device for pairing, then the charging station 50 cannot be paired with any of the available remote control devices 32 and may require the operator to repeat the pairing process.

[0138] Associate / pair the remote control device with the vehicle

[0139] Figures 16 - 18 illustrates details of an exemplary pairing process according to aspects of the present invention. The remote control device 32 and the vehicle 10 described above will be used to describe Figures 16 - 18The pairing process, 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] Reference Figure 16 , when at 502 the vehicle operator retrieves the remote control device 32, method 500 begins. If the remote control device 32 is a wearable device as in Figure 4 -FIG. 8 and Figures 9 - 10 the embodiment of, then the remote control device 32 is also worn by the operator, for example by fixing the retention strap 190 to the operator's finger(s).

[0141] Then, the vehicle operator initiates a power-on sequence to enable the vehicle 10 to operate, i.e., at 504 the operator starts the vehicle 10. When starting the vehicle 10, the operator may be required to provide login information to the vehicle 10. This information can be provided, for example, by entering a personal identification number (PIN) into the vehicle 10's control panel, by providing a login ID to the 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 the remote control device 32).

[0142] Then, at 506 the operator begins the pairing operation with the vehicle 10, and then at 508 the pairing system 34 pairs the remote control device 32 used by the operator with the vehicle 10. The details of two exemplary pairing operations will be described below with reference to Figure 17 and Figure 18 The details of two exemplary pairing operations will be described in detail.

[0143] Once paired, the system 8 can provide a visual indication, for example, by displaying a message on the vehicle 10, illuminating the LED 424 in a predetermined color, producing an audible or visual queue indicating that the pairing is complete, etc.

[0144] According to one aspect of the present invention, the remote control device 32 can be unpair ed from the vehicle 10 by turning off the power of 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] Respectively with reference to Figure 17 and Figure 18 The operations of two example pairing systems 34 are described, Figure 17 and Figure 18 are flowcharts of example methods 550 and 600 for pairing the vehicle 10 and the remote control device 32 using the pairing system 34, which is part of the charging station 50 on the vehicle 10 board. Figure 17 and Figure 18 The descriptions of methods 550 and 600 in Figure 16corresponds to step 506.

[0146] Referring Figure 17 to method 550, at 552, 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 to start scanning or listening for nearby BLE transmissions. As discussed above, the engagement of the first presence contact 212 with the second presence contact 222 may also enable the current limiter 406 such that power from the vehicle 10 can be provided from the charging element 220 to the charging contact 210, which will recharge the rechargeable power source 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 transmissions to pair the remote control device 32 with the vehicle controller 103, the remote control device 32 may be paired with the vehicle controller 103 through direct physical contact, for example, between the charging contact 210 and the charging element 220. Alternatively, dedicated pairing contacts (not shown) may 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 may engage with each other while the charging contact 210 engages with the charging element 220 such that the pairing process may occur simultaneously with the charging process. These pairing contacts may be used solely to perform the message exchange for the pairing operation.

[0147] According to one aspect of the present invention, in the case where the pairing process is completed wirelessly, at 554, the remote control device 32 detects the presence of voltage at its charging contact 210 and starts transmitting a BLE advertisement indicating that the remote control device 32 is available for communication with nearby devices via the wireless transmitter 178.

[0148] In response, the BLE radio transceiver 402 of the charging station 50 may receive one of the transmitted advertisements and, at 556, issue a BLE scan request directed to the specific remote control device 32 associated with the received advertisement. 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 advertisements from two or more remote control devices 32 while scanning or listening for nearby BLE transmissions, the vehicle 10 cannot be paired with any of the available remote control devices 32 and may 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.

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

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

[0151] At 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 564. Once paired, the vehicle 10 communicates wirelessly with the remote control device 32, and the controller 103 of the vehicle 10 is capable of implementing the wireless requests received from the remote control device 32.

[0152] In the example flowchart described above Figure 17 a similar method 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 above-described dedicated pairing contacts. Instead of transmitting and receiving messages via the wireless / BLE radio transceiver, messages of the same or equivalent type can be communicated via various protocols through the elements / contacts 220 / 210. The message can be modulated and transmitted on one of the elements / contacts 220 / 210 that provides voltage. In either case, the pairing of the vehicle 10 and the remote control device 32 can occur simultaneously with the charging of the rechargeable power supply 180 of the remote control device 32.

[0153] Reference Figure 18And 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 with a predetermined (e.g., 1500 ms) timeout to start 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 may also enable the current limiter 406 such that power from the vehicle 10 can be provided 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 operations are initiated by a single action of coupling the remote control device 32 to the charging station 50 such that the components of the remote control device 32 physically contact the elements of the charging station 50. Instead of using BLE transmissions to pair the remote control device 32 with the vehicle controller 103, the remote control device 32 may be paired with the vehicle controller 103 through direct physical contact, for example, between the charging contact 210 and the charging element 220. Alternatively, dedicated pairing contacts (not shown) may 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 may engage each other concurrently with the engagement of the charging contact 210 to the charging element 220 such that the pairing process may occur simultaneously with the charging process. These pairing contacts may be used solely to perform message exchanges for the pairing operation.

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

[0155] According to one aspect of the present invention, in the case where the pairing process is completed wirelessly, at 606, the remote control device 32 detects that voltage is present at its charging contact 210 and starts transmitting BLE advertisements at a predetermined rate (e.g., 20 ms rate) with a preset timeout (e.g., 2000 ms timeout) via the wireless transmitter 178 indicating that the remote control device 32 is available for communication with nearby vehicles 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 advertisements 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 may require 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 transmitting a BLE advertisement from the wireless transmitter 178, the charging station 50 may provide power to recharge the rechargeable power source 180 for up to approximately, for example, 1000 ms. The charging of the rechargeable power source 180 by the charging station 50 will be discussed in detail below.

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

[0158] At 610, the remote control device 32 receives the scan request from the BLE radio transceiver 402 and creates a unique identification code using the address of the BLE radio transceiver 402, which it sends back to the BLE radio transceiver 402 at 612.

[0159] At 614, the vehicle 10 verifies the code and instructs the BLE radio transceiver 402 to open a BLE connection and start communicating with the remote control device 32. It should be noted that if the vehicle 10 receives more than one valid identification code during step 614, for example, if the vehicle 10 receives identification codes from two different remote control devices 32, then the pairing will fail, the vehicle 10 will issue an error message or other warning, and the operator will be required 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.

[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 increase and return to the normal level.

[0161] At 620, the operator may be required to perform an action as a test to confirm that the remote control device 32 is functioning 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 concurrently pressing the horn button 197B and the brake button 197C.

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

[0163] According to aspects of the present invention, the pairing period (which is the time period taken to establish communication between the remote control device 32 and the vehicle 10, starting at step 552 / 602 and ending at step 564 / 616) may be less than the charging period (which is the time taken to charge the rechargeable power source 180 to a desired charge state at the charging station 50), where this will be described below in connection withFigure 21 and 22 discusses charging of the rechargeable power source 180.

[0164] Referring Figure 19 , according to another aspect of the present invention, after performing a work operation, a vehicle operator may need to temporarily leave the vehicle 10, e.g., to take a break. An exemplary method 700 is shown for turning off, restarting the vehicle 10, and re-pairing the vehicle 10 with a remote control device 32 used by the operator. At 702 the operator turns off the power of the vehicle 10 to take a break, etc. After a period of time, the vehicle operator reconnects the power of the vehicle 10. During this break period, the remote control device 32 may continue to be paired with the vehicle 10 for a predefined period of time. This state of maintaining the pairing between the vehicle 10 and the remote control device 32 can be indicated, for example, on a touch screen (not shown) provided on the vehicle 10 by illuminating an LED 424 with a predefined color, pattern, etc. Thus. If at 704 the operator powers on the vehicle 10 before the expiration of the predefined period, then at 706 the vehicle 10 can detect the remote control device 32, where the remote control device 32 remains paired with the vehicle 10. At this point, the operator may or may not have to take some type of action at 708, such as by pressing a button on the vehicle 10 (e.g., on the charging station 50, on the touch screen, 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 the pairing between the remote control device 32 and the vehicle 10 at 710. A visual queue may be displayed on an indicator (LED 424) to indicate the pairing, e.g., by illuminating the LED 424 with the second color as described above.

[0166] Alternatively, according to this aspect of the present invention, if the operator powers on the vehicle 10 after the expiration of the predefined period at 712, then the operator may be required to re-pair the remote control device 32 to the vehicle 10, as in the initial pairing, e.g., by inserting the remote control device 32 into the charging station 50 at 714.

[0167] Referring Figure 20, the exemplary method 800 is shown for re - establishing communication between the remote control device 32 and the vehicle 10 after a period of time during which no vehicle - related activities are performed. At 802, the controller 103 on the vehicle 10 detects that no vehicle - related activities have been performed within a given period of time after communication between the remote control device 32 and the vehicle 10 has been established. Exemplary vehicle - related activities include driving the vehicle 10 (either manually using the 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 activities have occurred within a time greater than a first predetermined amount of time after communication between the remote control device 32 and the vehicle 10 has been established, then the 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 state between the vehicle 10 and the remote control device 32 can be indicated on the touch screen, for example, by illuminating the LED 424 in a predetermined color, pattern, etc.

[0168] At 808, if no vehicle - related activities have occurred within a time less than a second predetermined amount of time after communication between the remote control device 32 and the vehicle 10 has been established, the second predetermined amount of time being equal to or less than the first predetermined amount of time, then the communication between the remote control device 32 and the vehicle 10 is terminated, but can be re - established without the pairing system 34, for example, by performing a confirmation method using the remote control device 32 at 810. The confirmation method can include, for example, the operator performing a sequence of buttons on the remote control device 32, such as by long - pressing one or more of the buttons 197A - C. This pairing state between the vehicle 10 and the remote control device 32 can be indicated on the touch screen, for example, by illuminating the LED 424 in a predetermined color, pattern, etc.

[0169] Figure 21 is a flowchart of an exemplary method 900 for charging a remote control device in accordance with the principles of the present invention. In particular, the remote control device can be the same as or similar to the remote control device 32 discussed herein and can include a wireless communication system 456 that includes a wireless transmitter 178 (e.g., capable of one - way or two - way communication), a rechargeable power source 180, and at least one control (e.g., controls 196A - C) that causes the wireless transmitter 178 to wirelessly transmit a request to the controller of the material handling vehicle 10.

[0170] Method 900 for charging remote control device 32 begins at 902 by initiating contact between components of remote control device 32 and elements of charging station 50, which is located at vehicle 10, and then sensing the contact between the remote control device components and the charging station elements. As described above, remote control device 32 can include one or more charging contacts 210, each charging contact 210 being arranged to engage a corresponding charging element 220 of 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 that the (one or more) charging contacts 210 and the (one or more) charging elements 220 are in contact with each other. However, other components of remote control device 32 and other elements of charging station 50 can be used to detect / sense the initiation of contact.

[0171] Next, at 904, a charging period is started, during which power is supplied from charging station 50 to rechargeable power source 180. As described above, by way of example, the circuitry of charging station 50 is configured such that after sensing contact between the (one or more) charging contacts 210 and the (one or more) charging elements 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 the substantially fully charged state), remote control device 32 can be removed from charging station 50.

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

[0173] Finally, after sensing this interruption at 906, at 908 charging station 50 can stop supplying power from charging station 50 to rechargeable power source 180, 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 the power supply from charging station 50 to rechargeable power source 180 to stop. The power supply from charging station 50 to rechargeable power source 180 can also be stopped when rechargeable power source 180 is charged to a desired amount (either fully charged or charged to a desired amount less than fully charged), as described herein.

[0174] Method 900 can include Figure 21Other optional steps shown in. For example, method 900 may further include, at 910, confirming the establishment of communication between the remote control device 32 and the vehicle 10, for example, using at least one of an audible or visual queue. Method 900 may further include, when the remote control device component contacts the charging station element, establishing communication (e.g., pairing) between the remote control device 32 and the vehicle 10 during a pairing period at 912, such that the controller 103 receives a transmission from the remote control device 32 and is able to implement a wireless request from the remote control device 32. Such communication between the remote control device 32 and the vehicle 10 may be established concurrently during charging of the rechargeable power source 180 at the 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.

[0175] In addition, method 900 may include, at 914, displaying the charging status of the rechargeable power source 180 at the vehicle 10 (e.g., at the charging station 50), where the charging status of the rechargeable power source 180 may be displayed at the vehicle 10 while charging the rechargeable power source 180 and during use of the remote control device 32. The charging status of the rechargeable power source 180 may be displayed, for example, via a series of lights, each light representing a level of the charging status of the rechargeable power source 180.

[0176] Figure 22 is a flowchart of another example method 950 for charging a remote control device (such as the remote control device 32 discussed herein), the remote control device including a wireless communication system 456 including a wireless transmitter 178 (e.g., capable of one-way or two-way communication), a rechargeable power source 180, and at least one control (e.g., controls 196A-C) that causes the wireless transmitter 178 to wirelessly transmit a request to the controller of the material handling vehicle 10. As used herein, the term "control," when used to describe the controls of the remote control device 32, means including any structure capable of providing a desired function, including but not limited to buttons, switches, dials, etc.

[0177] A method 950 for charging a remote control device 32 begins at 952 by initiating contact between components of the remote control device 32 and elements of a charging station 50 located at a vehicle 10, and then sensing the contact between the remote control device components and the charging station elements. As described above, the remote control device 32 can 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 the contact of the (one or more) charging contacts 210 and the (one or more) charging elements 220 with each other. However, other components of the remote control device 32 and other elements of the charging station 50 can be used to detect / sense the initiation of contact.

[0178] At 954, a current charging state of a rechargeable power source 180 is determined. Step 954 can be performed before or after step 952, i.e., the charging state of the rechargeable power source 180 can be communicated to the charging station 50 when the remote control device 32 is coupled to the charging station 50 and during use of the remote control device 32 by an operator, as discussed herein.

[0179] Based on the current charging state of the rechargeable power source 180 and after performing step 952, at 956, a charging period is initiated, during which power is supplied from the charging station 50 to the rechargeable power source 180. In one exemplary embodiment, at step 958A, if the voltage of the rechargeable power source 180 is below a voltage threshold VT, then the charging station 50 charges the rechargeable power source 180 at a higher first power level PL1. According to this embodiment, at step 958B, if the voltage of the rechargeable power source 180 is above the voltage threshold VT, then the charging station 50 charges the rechargeable power source 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, i.e., it can take approximately the same amount of time to charge the rechargeable power source 180 from above or below the voltage threshold VT to a desired amount. Although only two power levels PL1, PL2 associated with a single voltage threshold VT are discussed herein, additional voltage thresholds and power levels can be used, where the charging period can always be approximately the same amount of time regardless of the charging level of the rechargeable power source 180 when it is inserted into the charging station 50. Additionally, an equation can be used to dynamically set the power level based on the current charging state of the rechargeable power source 180.

[0180] Once the charging period is complete (i.e., once the rechargeable power source 180 is charged to a desired amount, i.e., substantially fully charged or charged to an amount less than substantially fully charged, e.g., in view of the sensed temperature if that technique is present in the system 8 or if less than full charge is desired), the remote control device 32 can be removed from the charging station 50.

[0181] Accordingly, Figure 22 the method at 960 continues, interrupts the contact between the remote control device component and the charging station element, and senses the interruption of the contact between the remote control device component and the charging station element. As described above, the (one or more) charging contacts 210 of the remote control device 32 and the (one or more) charging elements 220 of the charging station 50 are arranged such that when the two systems are disengaged, this state can be detected or sensed. One example is the second presence contact 222 that can detect when the remote control device 32 is removed from the charging station 50.

[0182] Finally, after sensing this interruption at 960, or after the rechargeable power source 180 is charged to the desired amount, at 962 the charging station 50 can stop supplying power from the charging station 50 to the rechargeable power source 180, thus ending the charging period.

[0183] Method 950 can include Figure 22 other optional steps as shown in. For example, method 950 can further include at 964 confirming the establishment of communication between the remote control device 32 and the vehicle 10, e.g., using at least one of an auditory or visual cue. Method 950 can further include, during the pairing period when the remote control device component is in contact with the charging station element, establishing communication (e.g., pairing) between the remote control device 32 and the vehicle 10 at 966 such that the controller 103 receives transmissions from the remote control device 32 and can implement wireless requests from the remote control device 32. Such communication between the remote control device 32 and the vehicle 10 can be established concurrently during the charging of the rechargeable power source 180 at the 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 can be greater than the charging period, as will be discussed in more detail below.

[0184] In addition, method 950 can include, at 968, displaying the charging status of the rechargeable power source 180 at the vehicle 10 (e.g., at the charging station 50), where the charging status of the rechargeable power source 180 can be displayed at the vehicle 10 when charging the rechargeable power source 180 and during use of the remote control device 32. The charging status of the rechargeable power source 180 can be displayed, for example, via a series of lights, each light representing a level of the charging status of the rechargeable power source 180.

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

[0186] Additionally, although the pairing period, described herein as the time period spent establishing 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 source 180 need not be fully charged to operate during a desired usage period. For example, a fully charged rechargeable power source 180 can provide more operating time than a desired usage period (e.g., an operator's shift), such that the rechargeable power source 180 need not be fully charged to operate during the desired usage period. In such a case, the charging station 50 can be programmed to charge the rechargeable power source 180 to a state less than fully charged, which is sufficient for the remote control device to remain operable throughout the desired usage period. The time taken to charge the rechargeable power source 180 to such a less than fully charged state can be less than the pairing period. Other situations where the charging period can be less than the pairing period can also occur.

[0187] Reference Figure 23 , the principles of the present invention can also be implemented as a kit 1000 for retrofitting a material handling vehicle 10'. In Figure 23 , elements that are similar or identical to those described above with reference to Figures 1 - 22 include the same reference numerals, followed by a prime ('), Regarding Figure 23 described but not specifically shown in Figure 23 , elements are equivalent to those having the same reference numerals as above but without the prime.

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

[0189] The kit 1000 can also include a pairing system 34' for establishing communication between the remote control device 32' and the vehicle 10', such that the controller 103' can implement wireless requests from the remote control device 32'. The pairing system 34' can be, for example, similar to the pairing system 34 and can implement Figure 17 and / or Figure 18The (one or more) pairing algorithms detailed therein. Accordingly, kit 1000 may also include a pairing indicator, e.g., a visual indicator 424', which confirms the establishment of communication between the remote control device 32' and the vehicle 10'. Additionally, the pairing system 34' may be configured such that the pairing period (the time period taken to establish communication between the remote control device 32' and the vehicle 10') may be less than or equal to the charging period (the time period taken to charge the rechargeable power source 180' to the desired amount). The pairing period may also be greater than the charging period. The pairing system 34' may be incorporated into the charging station 50' or may be a separate component.

[0190] It is contemplated that communication between the remote control device 32' and the vehicle 10' is established concurrently during charging of the rechargeable power source 180' at the charging station 50', i.e., the pairing period and the charging period may overlap. Additionally, in some embodiments, communication between the remote control device 32' and the vehicle 10' and charging of the rechargeable power source 180' at the charging station 50' are initiated with 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 may be the same as the remote control device 32 disclosed herein. Thus, a remote control device manufactured for use with a vehicle 10 including an integrated charging station 50 and associated components may also be used with kit 1000 for an existing vehicle 10'.

[0192] As described above with respect to the charging station 50, the charging station 50' of kit 1000 may also include a guiding structure 420' to align the remote control device 32' in a proper orientation for charging the rechargeable power source 180'.

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

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

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

[0196] Kit 1000 can also utilize non-contact or inductive charging, where the rechargeable power source 180' of the remote control device 32' can be charged by being brought near or placed on the surface of a compatible inductive charging station (not shown). For example, such an inductive charging station can be located in the driving or steering controls of the vehicle 10' such that the rechargeable power source 180' can be charged while the operator manually drives the vehicle 10' from the operating station 20'. The kit 1000 according to this aspect of the invention can be located at least partially in the vehicle steering control or other vehicle components that facilitate non-contact / inductive charging of the rechargeable power source 180'. For example, the rechargeable power source 180' can be charged by the operator grasping the driving / steering control.

[0197] Kit 1000 can utilize as described above for Figures 1 - 22Any other features and / or functions of the described remote control device 32' and charging station 50'. Note that if the vehicle 10' used with the kit 1000 was previously set up to interact with a wireless remote control device, then the controller logic in the vehicle controller 103' may need to be updated for use with the kit 1000, and the receiver already provided on the vehicle 10' (i.e., for receiving wireless requests from the remote control device used with the vehicle 10' before the kit 1000 was installed on the vehicle 10') can be turned off to be replaced with the receiver 102' of the kit 1000 (i.e., for use with the remote control device 32' associated with the kit 1000).

[0198] Now referring to Figure 24 , the remote control device 32 according to an embodiment of the present invention 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 finger 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 in Figures 4 - 7 can be the same or similar to the components of the remote control device 32 of Figures 4 - 7 , including the shape of the portion of the upper housing 174 that engages the charging station 50 at the vehicle 10. Thus, the charging station 50 at the vehicle 10 can be the same as the charging station 50 described above, i.e., since the charging station engaging portion of the upper housing 174 of the remote control device 32 incorporated into the glove garment 1100 can have the same dimensions as the charging station engaging portion of the upper housing 174 of the remote control device 32 in the embodiment of Figures 4 - 7 the finger-mounted remote control device 32 or the remote control device 32 incorporated into the Figure 24 glove garment 1100, the same charging station 50 can be used with either

[0199] If the remote control device 32 incorporated into the glove garment 1100 is used in combination with the inductive charging technology disclosed herein, then an inductive charging structure can be incorporated, for example, into the palm of the glove garment 1100. Such a charging structure in the glove garment 1100 can be used with a charging element, for example, incorporated into the steering control of a vehicle paired with the remote control device 32, in which case the rechargeable power source of the remote control device 32 can be charged while the operator is holding the steering control.

[0200] According to additional aspects of the present invention, there can be conditions and / or events that cause the vehicle 10 to become unpaired from the remote control device 32, where, as described herein, a full pairing process using the pairing system 34 can be required to re-pair the vehicle 10 with the remote control device 32. There can be other conditions or events that cause the vehicle 10 to become unpaired from the remote control device 32, where something other than a full pairing process using the pairing system 34 can be required, as described herein, to re-pair the vehicle 10 with the remote control device 32. Several exemplary use cases regarding un-pairing and re-pairing will now be described.

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

[0202] A second exemplary use case can be substantially as described above with respect to Figure 19 where the vehicle operator temporarily leaves the vehicle 10, e.g., to take a break. The details of this second exemplary use case were discussed above with reference to Figure 17 and will not be repeated.

[0203] Third and fourth exemplary use cases can occur if no vehicle-related activity occurs within a first predetermined amount of time 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 amount of time after communication is established between the remote control device 32 and the vehicle 10 (fourth use case). The details of these third and fourth exemplary use cases were discussed above with reference to Figure 20 and will not be repeated.

[0204] In cases involving multiple remote control devices 32 and / or multiple vehicles 10, multiple exemplary use cases can occur. 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 inserted into the 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 source 180 of the first remote control device 32, the first remote control device 32 can become unpaired with the first vehicle 10, and the second remote control device 32 can become unpaired with 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 a sixth exemplary use case and referring to Figure 24 , it is assumed that the remote control device 32 is currently paired with a first vehicle 10A such that the remote control device 32 communicates wirelessly with the first vehicle 10A, and a second vehicle 10B is currently not paired with the remote control device. In this sixth use case, the remote control device 32 uses a pairing process to pair with the second vehicle 10B, for example, by inserting the remote control device 32 into the charging station 50 of the second vehicle 10B. Using this pairing process, the charging station 50 of the second vehicle 10B can charge the rechargeable power source 180 of the remote control device 32, and the remote control device 32 can become paired with the second vehicle 10B such that the remote control device communicates wirelessly with the second vehicle 10B. This pairing process will also cause the remote control device to become unpaired with the first vehicle 10A such that the remote control device no longer communicates wirelessly with the first vehicle 10A. Once the remote control device 32 is paired with the second vehicle 10B and unpaired with the first vehicle 10A, the second vehicle 10B can respond to remote requests from the remote control device 32, while the first vehicle 10A can no longer respond to remote requests from the 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 source 180 of the remote control device 32 is being charged at the charging station 50, for example, to ensure that only remote control devices 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) are recognized as remote control devices 32 available for pairing with the second vehicle 10B.

[0207] According to the sixth exemplary use case, before 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 are located, a designated waiting area, etc.) by a warehouse management system WMS that communicates with the second vehicle 10B. The second vehicle 10B can be an unloaded vehicle (i.e., without a load) and is 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 the vehicle 10, such as a loading dock LD or other location to which the picked items on the first vehicle 10A will be sent), the second vehicle 10B can be instructed by the warehouse management system WMS to move to the designated location, for example. 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 can no longer execute commands from the warehouse management system WMS, such that the second vehicle 10B will only implement wireless commands from the remote control device 32 with which it is paired.

[0208] Once the remote control device 32 is unpair ed from the first vehicle 10A, the warehouse management system WMS can send an instruction to the first vehicle 10A to move to the loading dock LD and / or another location (such as a vehicle charging station (not shown)). Using this sixth exemplary use case, the operator can quickly switch between the vehicles 10A, 10B, thereby increasing 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 the 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 inserted into the charging station 50 of the vehicle 10. In this case, the charging station 50 of the vehicle 10 can charge the rechargeable power supply 180 of the second remote control device 32, the first remote control device 32 can become unpair ed from the vehicle 10, and the second remote control device 32 will not be paired with the vehicle 10.

[0210] In an eighth exemplary use case, the remote control device 32 is moved out of the range of the vehicle 10, i.e., such that 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 may become unpair ed from the vehicle 10. According to the eighth use case, if the remote control device 32 is moved back within the range of the vehicle 10 after the predetermined period of time, then 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 the previously paired remote control device 32 or a different remote control device 32. If the remote control device 32 is moved back within the range of the vehicle 10 within the predetermined period of time, then 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 may be re - paired with the vehicle 10 by inserting 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 was outside the range of the vehicle 10.

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

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

[0213] In a 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 source 180 according to the charge state of the rechargeable power source 180 when the remote control device 32 is inserted into the charging station 50, as described herein with respect to Figure 22 Regardless of the charge state of the rechargeable power source 180 when the remote control device 32 is inserted into the charging station 50, the charging period according to the tenth use case will always be approximately four seconds. Thus, a predictable charging period is achieved.

[0214] Note that the type of transmission sent from the remote control device 32 to the vehicle 10 (e.g., a request, such as a drive request) can be other types of transmissions. As an example, the transmission can include a location-based transmission that notifies 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. Such a 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 present invention, when the vehicle 10 is in motion, charging of the rechargeable power source 180 by the charging station 50 can be disabled. This aspect of the present invention may not apply to inductive charging of the rechargeable power source 180.

[0216] In addition, when an operator attempts to pair the remote control device 32 with the vehicle 10 that communicates with the warehouse management system WMS, the warehouse management system 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 an operation check can include, for example, performing a check to ensure the operability of the controls of the remote control device 32 (such as the horn and / or brake buttons 197B, 197C). If such an operation check has not been performed within the predetermined time period, then the vehicle 10 can communicate to the operator that the operation check must be performed before the remote control device 32 can be paired with the vehicle 10, i.e., the remote control device 32 is only allowed to be paired with the vehicle 10 if one or more remote control device operation checks have been performed within the predetermined time period. The operation check can be performed by the operator who implements the controls, for example, by holding down the horn and / or brake buttons 197B, 197C.

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

[0218] According to one aspect of the present invention, when it is determined that an operator is standing on the platform 21 of the vehicle 10, as detected by a presence sensor 22 for example, the charging life of the rechargeable power source 180 during a given operation cycle can be increased by shutting down 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 present invention are set forth in the following numbered clauses:

[0220] Clause

[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 for wirelessly controlling one or more functions of the vehicle and including:

[0223] A wireless transmitter;

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

[0225] A rechargeable power source;

[0226] A receiver at the vehicle for receiving transmissions from the wireless transmitter;

[0227] A controller at the vehicle, communicatively coupled to the receiver, the controller responsive to receipt of a request from the remote control device; and

[0228] A charging station at the vehicle, the charging station for charging the rechargeable power source of the remote control device.

[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 comprising a pairing system for establishing communication between the remote control device and the controller such that the controller will implement wireless requests from the remote control device.

[0231] 4. The system according to clause 3, wherein communication between the remote control device and the controller is currently established during charging of the rechargeable power source at the charging station.

[0232] 5. The system according to clause 3 or clause 4, wherein communication between the remote control device and the controller and charging of the rechargeable power source at the charging station are initiated with a single action.

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

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

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

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

[0237] 10. The system according to clause 9, wherein the substantially fully charged state of the rechargeable power source results in a usage period of the remote control device of at least two hours.

[0238] 11. The system according to clause 10, wherein the substantially fully charged state of the rechargeable power source results in a usage period of the remote control device of at least eight hours.

[0239] 12. The system according to any one of clauses 1 to 11, wherein a substantially fully charged state of the rechargeable power source is achieved by charging the rechargeable power source at the 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 proper orientation for charging the rechargeable power source.

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

[0242] 15. The system according to clause 14, wherein the indicator indicates the charging state of the rechargeable power source when the rechargeable power source is being charged at the charging station and during the use of the remote control device.

[0243] 16. The system according to clause 14 or clause 15, wherein the indicator includes a series of lights, each light representing a level of the charging 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 fixing the remote control device to one or more fingers of an 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 that engages 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 the charging station includes a switch for detecting whether the at least one charging contact is correctly engaged with the at least one corresponding charging element for charging the rechargeable power source, wherein if correct engagement is detected, then power transfer to the rechargeable power source is enabled by the charging station, and if correct engagement is not detected, then the charging station does not enable power transfer to the rechargeable power source.

[0248] 21. The system according to clause 20, wherein the structures of the remote control device and the charging station are configured such that before the at least one charging contact disengages from the at least one corresponding charging element, the switch indicates removal of the remote control device from the charging station, such that power transfer from the charging station to the rechargeable power source stops before the at least one charging contact disengages 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 that are positioned to engage corresponding charging elements on the 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 amount of time after communication is established between the remote control device and the controller, then communication between the remote control device and the controller terminates and the controller must be re-established to enable a 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 amount of time after communication is established between the remote control device and the controller, the second predetermined amount of time being less than the first predetermined amount of time, then communication between the remote control device and the controller is terminated, but can be re-established by performing a confirmation method using the remote control device.

[0252] 25. The system according to clause 24, wherein the confirmation method includes performing a button sequence on the remote control device.

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

[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 set point temperature, then the rechargeable power source is discharged to a high temperature charging state.

[0255] 28. The system according to clause 27, wherein the sensed temperature is an ambient temperature.

[0256] 29. The system according to clause 27 or clause 28, wherein the sensed temperature is a rechargeable power source temperature.

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

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

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

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

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

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

[0263] A charging station at the vehicle for charging a rechargeable power source of the remote control device; and

[0264] wherein the charging station is electrically coupled to a vehicle power source.

[0265] 36. The kit according to clause 35, further including a pairing system for establishing communication between the remote control device and the controller such that the controller will implement wireless requests from the remote control device.

[0266] 37. The kit according to clause 36, wherein the communication between the remote control device and the controller is established concurrently during the charging of the rechargeable power source at the charging station.

[0267] 38. The kit according to clause 36 or clause 37, wherein the communication between the remote control device and the controller and the charging of the rechargeable power source at the charging station are initiated with a single action.

[0268] 39. The kit according to clause 38, wherein the single action includes physically contacting a component of the remote control device with an element of the charging station.

[0269] 40. The kit according to any one of clauses 36 to 39, further comprising a pairing indicator for confirming 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 taken to establish communication between the remote control device and the controller is less than or equal to the pairing period.

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

[0272] 43. The kit according to clause 42, wherein the substantially fully charged state of the rechargeable power source results in a usage period of the remote control device of at least two hours.

[0273] 44. The kit according to clause 42 or clause 43, wherein the substantially fully charged state of the rechargeable power source results in a usage period of the remote control device of at least eight hours.

[0274] 45. The kit according to any one of clauses 35 to 44, wherein the substantially fully charged state of the rechargeable power source is achieved by charging the rechargeable power source at the charging station within 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 a proper orientation for charging the rechargeable power source.

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

[0277] 48. The kit according to clause 47, wherein the indicator indicates the charging state of the rechargeable power source when the rechargeable power source is being charged at the charging station and during the use of the remote control device.

[0278] 49. The kit according to clause 47 or clause 48, wherein the indicator includes a series of lights, each light indicating a level of the charging state of the rechargeable power source.

[0279] 50. The kit according to any one of clauses 35 to 49, wherein the remote control device includes at least one charging contact that engages 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 the charging station includes a switch that detects 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 power transfer to the rechargeable power source is enabled by the charging station, and if proper engagement is not detected, then the charging station does not enable power transfer to the rechargeable power source.

[0281] 52. The kit according to clause 51, wherein the structures of the remote control device and the charging station are configured such that before the at least one charging contact disengages from the at least one corresponding charging element, the switch indicates removal of the remote control device from the charging station, such that power transfer from the charging station to the rechargeable power source stops before the at least one charging contact disengages 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 that are positioned to engage corresponding charging elements on the charging station.

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

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

[0285] 56. The kit according to clause 55, wherein the sensed temperature is the ambient temperature.

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

[0287] 58. A method for charging a remote control device, the remote control device including a wireless transmitter, a rechargeable power source, 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 including:

[0288] Initiating contact between a component of the remote control device and an element of a charging station, the charging station being located at the vehicle;

[0289] Sensing the contact between the remote control device component and the charging station element;

[0290] After sensing the contact, powering the rechargeable power source from the charging station;

[0291] Interrupting the contact between the remote control device component and the charging station element;

[0292] Sensing the interruption of the contact between the remote control device component and the charging station element; and

[0293] After sensing the interruption, stopping powering the rechargeable power source from the charging station.

[0294] 59. The method according to clause 58, wherein the rechargeable power source is a supercapacitor.

[0295] 60. The method according to clause 58 or clause 59, further including establishing communication between the remote control device and the controller when the remote control device component is in contact with the charging station element, such that the controller will implement the 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 charging of the rechargeable power source at the charging station.

[0297] 62. The method according to clause 60 or clause 61, wherein the communication between the remote control device and the controller occurs during a pairing period, and charging of the rechargeable power source to a substantially full charge at the charging station occurs during a 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 including confirming the establishment of communication between the remote control device and the controller using at least one of an auditory or visual cue.

[0300] 65. The method according to any one of clauses 58 to 64, wherein a substantially full charge state of the rechargeable power source is achieved by charging the rechargeable power source at the charging station within five seconds or less.

[0301] 66. The method according to clause 65, wherein the substantially fully charged state of the rechargeable power source results in a usage period of the remote control device of at least two hours.

[0302] 67. The method according to clause 65 or clause 66, wherein the substantially fully charged state of the rechargeable power source results in a usage period of the remote control device of at least eight hours.

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

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

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

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

[0307] 72. The method according to any one of clauses 58 to 71, wherein initiating contact between the components of the remote control device and the elements of the charging station includes initiating 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 amount of time after communication is established between the remote control device and the controller, then communication between the remote control device and the controller is terminated and the controller must be re-established to enable a 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 amount of time after communication is established between the remote control device and the controller, the second predetermined amount of time being less than the first predetermined amount of time, then communication between the remote control device and the controller is terminated, but can be re-established by performing a confirmation method using the remote control device.

[0310] 75. The method according to clause 74, wherein the confirmation method includes performing a button sequence on the remote control device.

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

[0312] 77. A method according to any one of clauses 58 to 76, further comprising discharging the rechargeable power source to a high-temperature charging state if a sensed temperature is determined to be higher than a predetermined set-point temperature.

[0313] 78. A method according to clause 77, wherein the sensed temperature is an ambient temperature.

[0314] 79. A method according to clause 77 or clause 78, wherein the sensed temperature is a rechargeable power source temperature.

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

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

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

[0318] 83. A system comprising:

[0319] A material handling vehicle;

[0320] A remote control device, comprising:

[0321] A wireless communication system, comprising a wireless transmitter; and

[0322] A rechargeable power source;

[0323] A receiver at the vehicle for receiving transmissions from the wireless transmitter;

[0324] A controller at the vehicle communicatively coupled to the receiver, the controller responsive to receipt of a transmission from the remote control device; and

[0325] A charging station at the vehicle for charging the rechargeable power source of the remote control device.

[0326] 84. A kit for retrofitting a material handling vehicle, the vehicle including a controller responsive 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 including:

[0327] A charging station for the vehicle, the charging station being configured to be electrically coupled to a vehicle power source of the vehicle for charging a rechargeable power source of the remote control device.

[0328] 85. A method for charging a remote control device, the remote control device including a wireless communication system including a wireless transmitter and a rechargeable power source, the method including:

[0329] Initiating contact between a component of the remote control device and an element of the charging station, the charging station being located at the vehicle;

[0330] Sensing the contact between the remote control device component and the charging station element;

[0331] After sensing the contact, supplying power from the charging station to the rechargeable power source;

[0332] Interrupting the contact between the remote control device component and the charging station element;

[0333] Sensing the interruption of the contact between the remote control device component and the charging station element; and

[0334] After sensing the interruption, stopping the supply of power from the charging station to the rechargeable power source.

[0335] 86. The system according to clause 83, the kit according to clause 84, or the method according to clause 85, wherein the rechargeable power source is a supercapacitor.

[0336] 87. The system according to clause 83 or clause 86, or the kit according to clause 84 or clause 86, further including a pairing system for establishing communication between the remote control device and the vehicle; or

[0337] The method according to clause 85 or clause 86, further including establishing communication between the remote control device and the vehicle through the pairing system.

[0338] 88. The system according to 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] The kit according to clause 87, wherein the pairing system is configured to establish communication between the remote control device and the vehicle concurrently during charging of the rechargeable power source at the charging station; or

[0340] The method according to clause 87 further includes establishing communication between the remote control device and the vehicle concurrently during power supply from the charging station to the rechargeable power source.

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

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

[0343] The method according to clause 87 or clause 88 further includes initiating the communication between the remote control device and the vehicle and the charging of the rechargeable power source at the charging station with a single action.

[0344] 90. The system or kit according to clause 89, wherein the single action includes physically contacting a component of the remote control device with an element of the charging station; or

[0345] The method according to clause 89, wherein the single action includes physically contacting a remote control device component with a charging station element.

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

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

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

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

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

[0352] 94. The system, kit or method according to clause 93, wherein the confirmation method includes performing a button sequence on the remote control device.

[0353] 95. The system according to any one of clauses 83 or 86 to 94, the kit according to any one of clauses 84 or 86 to 94, or the method according to any one of clauses 85 to 94, wherein the substantially fully charged state of the rechargeable power source is achieved by charging the rechargeable power source at the charging station within five seconds or less, and wherein the substantially fully charged state of the rechargeable power source results in a usage period of at least two hours for the remote control 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 state of the rechargeable power source, wherein the indicator indicates the charging state of the rechargeable power source when the rechargeable power source is being charged at the charging station and during the use of the remote control device;

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

[0356] The method according to any one of clauses 85 to 95 further includes indicating the charging state of the rechargeable power source by an indicator both when the rechargeable power source is being charged at the charging station and during the 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 the charging station; or

[0358] The kit according to any one of clauses 84 or 86 to 96, wherein the charging station includes at least one charging element configured to engage at least one corresponding charging contact of the remote control device.

[0359] 98. The system or kit according to clause 97, wherein at least one of the remote control device or the charging station includes a presence contact that detects whether the at least one charging contact is correctly engaged with the at least one corresponding charging element for charging the rechargeable power source, wherein if correct engagement is detected, then power transfer to the rechargeable power source is enabled by the charging station, and if correct engagement is not detected, then the charging station does not enable power transfer to the rechargeable power source; or

[0360] The method according to clause 97, further comprising detecting, via the presence contact, whether the at least one charging contact is correctly engaged with the at least one corresponding charging element for charging the rechargeable power source, and if correct engagement is detected, then enabling power supply from the charging station to the rechargeable power source, and if correct engagement is not detected, then not enabling power supply from the charging station to the rechargeable power source.

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

[0362] The kit according to clause 98, wherein, before the at least one charging contact disengages from the at least one corresponding charging element, the presence contact is configured to indicate removal of the remote control device from the charging station, which stops power transfer from the charging station to the rechargeable power source, such that power transfer from the charging station to the rechargeable power source is stopped before the at least one charging contact disengages from the at least one corresponding charging element; or

[0363] The method according to clause 98 further includes indicating, via a presence contact, the removal of the remote control device from the charging station before the at least one charging contact is detached from the at least one corresponding charging element, thereby stopping the power transfer from the charging station to the rechargeable power source, such that the power supply from the charging station to the rechargeable power source is stopped before the at least one charging contact is detached from the at least one corresponding charging element.

[0364] 100. The system according to any one of clauses 83 or 86 to 99, or the 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 set point temperature, then the rechargeable power source is discharged to a high temperature charging state, the sensed temperature being (i) the ambient temperature, or (ii) the temperature of the rechargeable power source; or

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

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

[0367] The kit according to any one of clauses 84 or 86 to 100, wherein if the sensed temperature is determined to be higher than a predetermined threshold temperature, then the charging station is configured to charge the rechargeable power source to a predetermined charging level below 100% charge level; or

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

[0369] 102. The system according to any one of clauses 83 or 86 to 101, or the method according to any one of clauses 85 to 101, wherein the charging station is located at a 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 at a side of the vehicle.

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

[0372] 104. The system according to any one of clauses 83 or 86 to 103, or the kit according to any one of clauses 84 or 86 to 103, wherein one or more components of the remote control device are turned off or the power supplied thereto is reduced when the operator is positioned on the vehicle; or

[0373] The method according to any one of clauses 85 to 103, further comprising turning off one or more components of the remote control device or reducing the power supplied thereto when the operator is positioned on the vehicle.

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

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

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

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

[0378] The method according to any one of clauses 85 to 104, further comprising:

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

[0380] If the voltage of the rechargeable power supply before being charged by the charging station is higher than the voltage threshold, then charge the rechargeable power supply at a 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 regardless of whether the voltage of the rechargeable power supply before being charged by the charging station is higher or lower than the voltage threshold, the charging station charges the rechargeable power supply to a substantially fully charged state in approximately the same time; or

[0383] The kit according to clause 105, wherein the charging station is configured to charge the rechargeable power source to a substantially fully charged state in approximately the same amount of time regardless of whether the voltage of the rechargeable power source before being charged by the charging station is higher or lower than a voltage threshold; or

[0384] The method according to clause 105, further comprising charging the rechargeable power source to a substantially fully charged state in approximately the same amount of time regardless of whether the voltage of the rechargeable power source before being charged by the charging station is higher or lower than a voltage threshold.

[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 a wireless communication system, and 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, and the method further includes transmitting a request to the vehicle via the wireless transmitter after actuation of the control.

[0387] 108. A system, comprising:

[0388] A vehicle;

[0389] A remote control device, comprising:

[0390] A wireless communication system including a wireless transmitter; and

[0391] A rechargeable power source;

[0392] A charging station located at the vehicle for charging the rechargeable power source of the remote control device; and

[0393] A sensor configured to detect contact between a component of the remote control device and an element of the charging station,

[0394] wherein 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 element, and to stop supplying power from the charging station to the rechargeable power source after interrupting the contact between the remote control device component and the charging station element;

[0395] And optionally includes one or more of the system features described in any one of clauses 2 to 34, 82, and / or 84 to 105.

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

[0397] Receiving a transmission from the wireless transmitter at a receiver at the vehicle;

[0398] In response to receiving the transmission from the remote control device at a controller at the vehicle, the controller being communicatively coupled to the receiver; and

[0399] Charging the rechargeable power source of the remote control device via a charging station at the vehicle;

[0400] And optionally including one or more of the method steps as described in any one of clauses 59 - 81.

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

[0402] A charging station for the vehicle, the charging station being configured to be electrically coupled to a vehicle power source of the vehicle for charging a rechargeable power source of a remote control device;

[0403] And optionally including one or more of the kit features as described in any one of clauses 36 - 57.

[0404] 111. A system, comprising:

[0405] A kit as described in clause 108;

[0406] A material handling vehicle;

[0407] A remote control device, comprising:

[0408] A wireless communication system comprising a wireless transmitter; and

[0409] A rechargeable power source;

[0410] A receiver at the vehicle for receiving a transmission from the wireless transmitter; and

[0411] A controller at the vehicle, communicatively coupled to the receiver, the controller responding to the receipt of a transmission from the remote control device;

[0412] And optionally including one or more of the system features as described in any one of clauses 2 to 34, 82 and / or 84 to 105.

[0413] It should be understood that features described as optional features of the system of clause 1 and 83, the kit of clause 35 and 84, and the method of clause 58 and 85, as described in clauses 2 to 34, 36 - 57, 59 - 82, and 86 to 107 listed below, are also intended to be combined with one or more of the system of clause 106 and / or 109, the method of clause 107, and the kit of clause 108.

[0414] In addition, features described as optional features of the system of clause 1, the kit of clause 35, and the method of clause 58 are intended to be combined with one or more of the system of clause 83, the kit of clause 84, and the method of clause 85. Further, features described as optional features of the system of clause 83, the kit of clause 84, and the method of clause 85 are intended to be combined with one or more of the system of clause 1, the kit 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 herein to describe a security process whereby a wireless remote control device and a vehicle controller identify each other as valid command and response devices.

[0416] The invention of the present application has been described in such detail and with reference to the embodiments of the present application that 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 system, comprising: Material handling vehicle; Remote control device, comprising: A wireless communication system including a wireless transmitter; A rechargeable power supply; and At least one charging contact; A receiver at the vehicle for receiving transmissions from the wireless transmitter; A controller at the vehicle communicatively coupled to the receiver, the controller responsive to receipt of a transmission from the remote control device; A charging station at the vehicle, the charging station for charging the rechargeable power supply of the remote control device via the at least one charging contact; and 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 both when the rechargeable power supply is being charged at the charging station and during use of the remote control device.

2. The system according to claim 1, wherein the at least one charging contact engages at least one corresponding charging element on a charging station.

3. The system according to claim 2, wherein at least one of a remote control device or a charging station includes a presence contact that detects 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 power transfer to the rechargeable power source is enabled by the charging station, and if proper engagement is not detected, then power transfer to the rechargeable power source is not enabled by the charging station.

4. A system, comprising: Material handling vehicle; Remote control device, comprising: A wireless communication system including a wireless transmitter; A rechargeable power supply; and At least one charging contact; A receiver at the vehicle for receiving transmissions from the wireless transmitter; A controller at the vehicle communicatively coupled to the receiver, the controller responsive to receipt of a transmission from the remote control device; and A charging station at the vehicle, the charging station for charging the rechargeable power supply of the remote control device via the at least one charging contact and including at least one charging element adapted to be engaged by the at least one charging contact of the remote control device; Wherein at least one of the remote control device or the charging station includes a presence contact for detecting whether the at least one charging contact is correctly engaged with at least one corresponding charging element for charging the rechargeable power supply, wherein if correct engagement is detected, then power transfer to the rechargeable power supply is enabled by the charging station, and if correct engagement is not detected, then the charging station does not enable power transfer to the rechargeable power supply.

5. A system, comprising: Material handling vehicle; Remote control device, comprising: A wireless communication system including a wireless transmitter; A rechargeable power supply; and At least one charging contact; A receiver at the vehicle for receiving transmissions from the wireless transmitter; A controller at the vehicle communicatively coupled to the receiver, the controller responsive to receipt of a transmission from the remote control device; A charging station at the vehicle, the charging station for charging the rechargeable power supply of the remote control device via the at least one charging contact; and A pairing system for establishing communication between the remote control device and the vehicle; Wherein the wireless communication system enters a low power mode when the rechargeable power supply of the remote control device is being charged at the charging station; Wherein communication between the remote control device and the vehicle and charging of the rechargeable power supply at the charging station are initiated with a single action.

6. A system, comprising: Material handling vehicle; Remote control device, comprising: A wireless communication system including a wireless transmitter; A rechargeable power supply; and At least one charging contact; A receiver at the vehicle for receiving transmissions from the wireless transmitter; A controller at the vehicle communicatively coupled to the receiver, the controller responsive to receipt of a transmission from the remote control device; and A charging station at the vehicle, the charging station for charging the rechargeable power supply of the remote control device via the at least one charging contact; One or more components of the remote control device are turned off or the power supplied thereto is reduced when the operator is located on the vehicle.

7. The system according to claim 5 or claim 6, wherein: The at least one charging contact engages at least one corresponding charging element at a charging station; At least one of the remote control device or the charging station includes a presence contact that detects whether the at least one charging contact is correctly engaged with the at least one corresponding charging element for charging a rechargeable power source, wherein if correct engagement is detected, then power transfer to the rechargeable power source is enabled by the charging station, and if correct engagement is not detected, then power transfer to the rechargeable power source is not enabled by the charging station; And The arrangement of the remote control device and the charging station is configured such that before the at least one charging contact disengages from the at least one corresponding charging element, the presence contact indicates removal of the remote control device from the charging station, which stops power transfer from the charging station to the rechargeable power source, such that power transfer from the charging station to the rechargeable power source is stopped before the at least one charging contact disengages from the at least one corresponding charging element.

8. The system according to any one of claims 1 - 6, wherein the rechargeable power source is a supercapacitor.

9. The system according to any one of claims 1 - 6, further comprising a pairing system for establishing communication between a remote control device and a vehicle.

10. The system according to claim 9, wherein communication between the remote control device and the vehicle is concurrently established using the pairing system during charging of the rechargeable power source at a charging station.

11. The system according to claim 9, further comprising a pairing indicator for confirming the establishment of communication between the remote control device and the vehicle.

12. The system according to claim 9, wherein communication between the remote control device and the vehicle and charging of the rechargeable power source at a charging station are initiated with a single action.

13. The system according to claim 12, wherein the single action includes physically contacting a component of the remote control device with an element of the charging station.

14. The system according to claim 9, wherein if no vehicle - related activity occurs within a first predetermined amount of time after communication between the remote control device and the vehicle is established, then communication between the remote control device and the vehicle is terminated and must be re - established using the pairing system; and If no vehicle-related activity occurs within less than a second predetermined amount of time after communication is established between the remote control device and the vehicle, the second predetermined amount of time being equal to or less than the first predetermined amount of time, then the communication between the remote control device and the vehicle is terminated, but can be re-established by performing a confirmation method using the remote control device without a pairing system.

15. The system according to claim 14, wherein the confirmation method includes performing a button sequence on the remote control device.

16. The system according to claim 3 or claim 4, wherein the arrangement of the remote control device and the charging station is configured such that there is an indication of 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, 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 disengages from the at least one corresponding charging element.

17. The system according to any one of claims 1-6, wherein if the sensed temperature is determined to be higher than a predetermined setpoint temperature, then the rechargeable power source is discharged to a high-temperature charging state, the sensed temperature being: the ambient temperature; or the temperature of the rechargeable power source.

18. The system according to any one of claims 1-6, wherein if the sensed temperature is determined to be higher than a predetermined threshold temperature, then the rechargeable power source is charged at the charging station to a predetermined charge level below 100% charge level.

19. The system according to any one of claims 1-4 or 6, wherein the wireless communication system enters a low-power mode when the rechargeable power source of the remote control device is being charged at the charging station.

20. The system according to any one of claims 1-5, wherein one or more components of the remote control device are turned off or the power supplied thereto is reduced when the operator is located on the vehicle.

21. The system according to any one of claims 1-6, wherein: If the voltage of the rechargeable power source before being charged by the charging station is lower than a voltage threshold, then the charging station charges the rechargeable power source at a first power level; If the voltage of the rechargeable power source before being charged by the charging station is higher than a voltage threshold, then the charging station charges the rechargeable power source at a second power level; And The first power level is greater than the second power level.

22. The system according to claim 21, wherein the charging station charges the rechargeable power source to a substantially fully charged state in approximately the same time regardless of whether the voltage of the rechargeable power source before being charged by the charging station is higher or lower than the voltage threshold.

23. The system according to any one of claims 1-6, wherein a substantially fully charged state of the rechargeable power source is achieved by charging the rechargeable power source at a charging station in five seconds or less, and wherein the substantially fully charged state of the rechargeable power source results in a usage period of the remote control device of at least two hours.

24. The system according to any one of claims 1-6, wherein the remote control device includes at least one control communicatively coupled to the wireless communication system, and actuation of the control causes the wireless transmitter to wirelessly transmit a request to the vehicle.

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