High-position picking forklift safety system and driving safety control method

Abstract

The invention discloses a high-position picking forklift system. The system comprises a whole vehicle controller; the sensor part is in signal communication with the vehicle control unit and used for transmitting a detection signal to the vehicle control unit, and the sensor part comprises a tilt angle sensor, a proximity sensor and an infrared sensor; the driving accelerator is in signal communication with the vehicle control unit and is used for transmitting a driving control signal to the vehicle control unit; the lifting and descending switch is in signal connection with the whole vehicle controller and is used for transmitting a picking vehicle lifting or descending signal to the whole vehicle controller; the execution part comprises a picking vehicle driving assembly and a picking vehicle lifting assembly, and the execution part is communicated with the whole vehicle controller, receives the control signal and executes the control signal. The inclination angle sensor is designed and installed to detect the inclination angle of the whole vehicle and further recognize the ramp driving working condition of the picking vehicle, and the slope of the driving road surface is associated with the driving control strategy of the picking vehicle; and driving strategy control under different gradients is carried out, so that the driving safety is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of forklift safety, and in particular to a safety system for a high-position picking forklift and a driving safety control method. Background Art

[0002] High-level picking forklifts (hereinafter referred to as "picking trucks") are suitable for picking operations in high-level and high-density warehouses. During operation, the driver and the goods are lifted together. To ensure the efficiency of picking operations, the whole vehicle must meet the driving and operation requirements when it is at a high level. At present, when picking trucks are driving at a high level (the maximum lifting height in the industry is about 13m), the driver mainly observes and judges to operate the vehicle. Some blind spots and road conditions cannot be accurately judged. The only way to improve the safety of the picking truck is to increase the effective field of view by lowering the lifting height. This operation is time-consuming and labor-intensive, and also reduces work efficiency. Summary of the invention

[0003] The object of the present invention is to provide a high-position picking forklift safety system and a driving safety control method to solve the problems raised in the above-mentioned background technology.

[0004] To achieve the above object, the present invention provides the following technical solutions:

[0005] A high-position picking forklift system, comprising:

[0006] Vehicle controller;

[0007] A sensor unit, the sensor unit is in signal communication with the vehicle controller for transmitting a detection signal to the vehicle controller, the sensor unit comprising a tilt sensor, a proximity sensor, and an infrared sensor;

[0008] A driving accelerator, connected to the vehicle controller by signal, and used to transmit a driving control signal to the vehicle controller;

[0009] A lifting and lowering switch is connected to the vehicle controller signal and is used to transmit a lifting or lowering signal of the picking vehicle to the vehicle controller;

[0010] The execution unit includes a picking vehicle traveling component and a picking vehicle lifting component, which are connected to the vehicle controller, receive control signals from the vehicle controller and execute.

[0011] As a further solution of the present invention: the proximity sensor includes a first proximity sensor arranged at the front of the picking vehicle and a second proximity sensor arranged at the rear of the picking vehicle.

[0012] As a further solution of the present invention: the infrared sensor includes a first infrared sensor arranged at the front of the picking vehicle and a second infrared sensor arranged at the rear of the picking vehicle.

[0013] As a further solution of the present invention: the vehicle controller signal is connected to a display unit, and the display unit includes an instrument for displaying status information of the picking vehicle.

[0014] As a further solution of the present invention: the vehicle controller is connected to a buzzer, and a relay is connected between the buzzer and the vehicle controller.

[0015] As a further solution of the present invention: the picking vehicle traveling component includes a traction motor connected to the vehicle controller signal and a driving wheel assembly connected to the traction motor power; the picking vehicle lifting component includes an oil pump motor connected to the vehicle controller signal; the oil pump motor power is connected to a gear pump; and the gear pump is connected to a lifting cylinder through an oil circuit.

[0016] A method for controlling the driving safety of a high-position picking forklift, comprising the following steps:

[0017] Step, the vehicle controller receives signals from the tilt sensor, the proximity sensor, and the infrared sensor, and processes the signals;

[0018] Step 2: Obtain the current tilt angle A of the picking vehicle through the tilt sensor 1. If A≠0, execute step 3; otherwise, execute step 3;

[0019] Step 3: Compare the current tilt angle A of the picking vehicle with the judgment thresholds A1 and A2. If A>A1, the vehicle controller controls the display unit to issue a "warning" signal; if A>A2, the vehicle controller controls the display unit to issue a "limit" signal, where A1 is the maximum climbing angle designed for the vehicle, and A2 is the maximum safe climbing angle of the vehicle;

[0020] Step 4, determine the driving direction of the picking vehicle and the signals of the proximity sensor and the infrared sensor. When the picking vehicle is driving forward and the first proximity sensor and / or the first infrared sensor in front of the picking vehicle receive a detection signal, execute step 5; when the picking vehicle is driving backward and the second proximity sensor and / or the second infrared sensor in the rear of the picking vehicle receive a detection signal, execute step 5;

[0021] Step 5: The vehicle controller issues a warning through a buzzer, and displays the real-time distance of the detected obstacle through the display unit. When the distance is less than the preset distance, the picking vehicle starts braking.

[0022] As a further solution of the present invention: the driving accelerator inputs an analog voltage signal C1 to the vehicle controller, and 0V<C1<12V, when 0.5V<C1<5.5V, the vehicle controller controls the traction motor to rotate forward, driving the drive wheel assembly to rotate forward, and the picking vehicle moves forward; when 6.5V<C1<11.5V, the vehicle controller controls the traction motor to reverse, driving the drive wheel assembly to rotate backward, and the picking vehicle moves backward; when 0V<C1<0.5V, 5.5V<C1<6.5V, and 11.5V<C1<12V, the dead zone voltage is set.

[0023] As a further solution of the present invention: the buzzer relay, the buzzer and the vehicle controller are connected in series, the loop is closed by triggering the buzzer relay, the buzzer is powered and emits a warning sound, the input switch signal of the buzzer is C2, when C2=1, the loop is closed, otherwise it is disconnected when C2=0;

[0024] The lifting and lowering switch independently inputs the lifting analog signal C or the lowering switch signal C to the vehicle controller. The vehicle controller detects the lifting analog signal C4, and the value range of C4 is: 0V<C4<12V;

[0025] When 0.5V<C4<11.5V, the gear pump is driven by controlling the rotation of the oil pump motor, thereby realizing the oil supply to the lifting cylinder and lifting the mast. When the vehicle controller detects the descending switch signal C3=1, the mast descends, otherwise C3=0 and the mast does not move.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. This application is designed to install an inclination sensor to detect the inclination angle of the whole vehicle and then identify the "slope driving" working condition of the picking vehicle, so as to associate the driving road slope with the driving control strategy of the picking vehicle, and control the driving strategy under different slopes, thereby improving driving safety and allowing the driver to accurately grasp the road condition information when in a high position, thereby avoiding the need to lower the picking vehicle mast to a low position before operating the whole vehicle, which causes a decrease in work efficiency;

[0028] 2. This application designs and installs sensors in front and rear of the picking vehicle to identify whether there are obstacles or pedestrians in front and behind the picking vehicle's driving path and calculate the distance for the controller to make driving decisions, thereby avoiding accidents caused by unsafe driving due to blind spots in the driver's field of vision. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a schematic diagram of the control principle of this embodiment;

[0030] In the figure: 1-tilt sensor, 2-vehicle controller, 3-first proximity sensor, 4-second proximity sensor, 5-first infrared sensor, 6-second infrared sensor, 7-display unit, 8-driving accelerator, 9-relay, 10-buzzer, 11-traction motor, 12-driving wheel assembly, 13-lifting and lowering switch, 14-oil pump motor, 15-gear pump, 16-lifting cylinder. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] See also Figure 1 In an embodiment of the present invention, a high-position picking forklift system includes:

[0033] The vehicle controller 2 is connected to a display unit 7 by signal. The display unit 7 includes an instrument for displaying the state information of the picking vehicle. The vehicle controller 2 is connected to a buzzer 10. A relay 9 is connected between the buzzer 10 and the vehicle controller 2.

[0034] The sensor unit is connected to the vehicle controller 2 by signal and is used to transmit the detection signal to the vehicle controller. The sensor unit includes a tilt sensor 1, a proximity sensor, and an infrared sensor. In this embodiment, the proximity sensor includes a first proximity sensor 3 arranged at the front of the picking vehicle and a second proximity sensor 4 arranged at the rear of the picking vehicle. The infrared sensor includes a first infrared sensor 5 arranged at the front of the picking vehicle and a second infrared sensor 6 arranged at the rear of the picking vehicle.

[0035] The driving accelerator 8 is connected to the vehicle controller 2 by signal, and is used to transmit a driving control signal to the vehicle controller 2;

[0036] The lifting and lowering switch 13 is connected to the vehicle controller 2 signal, and is used to transmit the lifting or lowering signal of the picking vehicle to the vehicle controller 2;

[0037] The execution unit includes a picking vehicle travel component and a picking vehicle lifting component, which are connected to the vehicle controller 2, receive control signals from the vehicle controller 2 and execute. In this embodiment, the picking vehicle travel component includes a traction motor 11 connected to the signal of the vehicle controller 2 and a drive wheel assembly 12 connected to the power of the traction motor 11. The picking vehicle lifting component includes an oil pump motor 14 connected to the signal of the vehicle controller 2. The oil pump motor is powered by a gear pump 15, and the gear pump 15 is connected to a lifting cylinder 16 through an oil circuit.

[0038] A driving safety control method for a high-position picking forklift, wherein a vehicle controller 2 and a display unit 7 transmit signals via a CAN signal; a driving accelerator 8 inputs an analog voltage signal C1 (0V<C1<12V) to the vehicle controller 2; when 0.5V<C1<5.5V, the vehicle controller 2 controls the traction motor 11 to rotate forward, driving the drive wheel assembly 12 to rotate forward, and the picking vehicle moves forward; when 6.5V<C1<11.5V, the vehicle controller 2 controls the traction motor 11 to rotate reversely, driving the drive wheel assembly 12 to rotate backward, and the picking vehicle moves backward; when 0V<C1<0.5V, 5.5V<C1<6.5V, and 11.5V<C1<12V, a dead zone voltage is set to prevent misoperation from causing a bad driving experience);

[0039] The buzzer relay 9 and the buzzer 10 are connected in series with the vehicle controller 2. The loop is closed by triggering the buzzer relay 9 (the input switch signal is C2, when C2=1, the loop is closed, otherwise it is disconnected when C2=0), and the buzzer 10 is powered to emit a warning sound;

[0040] The lifting and lowering switch 13 independently inputs the lifting analog signal C4 or the lowering switch signal C3 to the vehicle controller 2. When the vehicle controller 2 detects the lifting analog signal C4 (0V<C4<12V), when 0.5V<C4<11.5V, the gear pump 15 is driven by controlling the oil pump motor 14 to rotate (0V<C4<0.5V, 11.5V<C4<12V are set as dead zone voltages, and the C4 voltage value is positively correlated with the speed of the oil pump motor 14), thereby realizing the oil supply to the lifting cylinder 16 and lifting the mast. When the vehicle controller 2 detects the lowering switch signal C3=1, the mast lowering action is executed, otherwise C3=0 the mast has no action.

[0041] The following steps are involved:

[0042] Step 1, the vehicle controller 2 receives signals from the tilt sensor 1, the proximity sensor, and the infrared sensor, and processes the signals;

[0043] Step 2: Obtain the current tilt angle A of the picking vehicle through the tilt sensor 1. If A≠0, execute step 3; otherwise, execute step 4.

[0044] Step 3, compare the current picking vehicle inclination angle A with the judgment thresholds A1 and A2, where A1 is the maximum climbing gradient designed for the vehicle, and A2 is the maximum inclination angle for safe driving of the vehicle. If A>A1, the vehicle controller 2 controls the display unit 7 to issue a "warning" signal; if A>A2, the vehicle controller 2 controls the display unit 7 to issue a "restriction" signal;

[0045] In this embodiment, A1 = 5°, A2 = 8°.

[0046] In this embodiment, the inclination sensor 1 is installed on the picking vehicle and detects the inclination angle of the vehicle in real time. When it is determined that the picking vehicle is driving on a slope (especially when the picking vehicle is in a high cargo position state), the inclination sensor 1 inputs the detected inclination angle A of the picking vehicle into the vehicle controller 2 for determination. When A≤A1, the vehicle can drive and operate normally.

[0047] When A>A1, the vehicle controller 2 controls the intelligent instrument 7 to send out a "warning" signal, giving similar reminder information such as the tilt angle of the picking vehicle is too large, informing the driver to drive carefully, and the vehicle controller 2 limits the operation of the oil pump motor 14, prohibiting the mast lifting action, and can trigger the lowering command through the lifting and lowering switch 13 to realize the mast lowering action;

[0048] When A>A2, the vehicle controller 2 controls the intelligent instrument 7 to send a "limit" signal. The vehicle controller 2 limits the operation of the oil pump motor 14 and prohibits the gantry lifting action. The lifting / lowering switch 13 can trigger a lowering command to realize the gantry lowering action. In addition, the vehicle controller 2 limits the forward (or reverse) operation of the traction motor 11. The traction motor 11 can only reverse (or rotate), thereby prohibiting the picking vehicle from continuing to drive on a steep road surface and can only perform downhill driving operations, effectively avoiding dangerous situations such as rollover caused by the driver's inability to subjectively judge the slope of the slope when driving the picking vehicle, thereby improving driving safety.

[0049] Step 4, determine the driving direction of the picking vehicle and the signals of the proximity sensor and the infrared sensor. When the picking vehicle is driving forward and the first proximity sensor 3 and / or the first infrared sensor 5 in front of the picking vehicle receive the detection signal, execute step 5; when the picking vehicle is driving backward and the second proximity sensor 4 and / or the second infrared sensor 6 at the rear of the picking vehicle receive the detection signal, execute step 5;

[0050] Step 5: The vehicle controller 2 issues a warning through the buzzer 10, and displays the real-time distance of the detected obstacle through the display unit 7. When the distance is less than the preset value, the picking vehicle starts braking.

[0051] In this embodiment, when the picking vehicle is in operation (especially when the picking vehicle is in a high cargo position), the picking vehicle cannot effectively judge the people or obstacles in front of or behind the vehicle due to its limited field of vision. The displacement proximity sensor (for judging distance) and infrared sensor (for judging people or objects) installed on the picking vehicle send signals to the vehicle controller 2 for intelligent control and reminder. The first proximity sensor 3 and the first infrared sensor 5 are installed in front of the picking vehicle's driving path, and the second proximity sensor 4 and the second infrared sensor 6 are installed behind the picking vehicle's driving path.

[0052] When the first infrared sensor 5 detects that there is a person or object in front of the picking vehicle's driving path (the maximum detection distance is set to L0), the vehicle controller 2 detects the voltage signal C1 sent by the driving accelerator 8.

[0053] When 0.5V<C1<5.5V, the vehicle controller 2 controls the traction motor 11 to rotate forward to realize the forward movement of the picking vehicle. At this time, the vehicle controller 2 sends a closing command (C2=1) to the buzzer relay 9, and the buzzer 10 is energized to emit a warning sound. In addition, the first proximity sensor 3 detects the distance L in real time and displays the distance parameter through the smart meter 7 in real time. When L≤L1 (L1<L0), the vehicle controller 2 restricts the forward movement of the picking vehicle or issues a braking command;

[0054] When C1≤0.5V or C1≥5.5V, the buzzer relay 9 does not work (C2=0), and the vehicle operates normally.

[0055] When the second infrared sensor 6 detects that there is a person or object behind the picking vehicle's driving path (the maximum detection distance is set to L0), the vehicle controller 2 detects the voltage signal C1 sent by the driving accelerator 8.

[0056] When 6.5V<C1<11.5V, the vehicle controller 2 controls the traction motor 11 to reverse and realize the picking vehicle to move backward. At this time, the vehicle controller 2 sends a closing command (C2=1) to the buzzer relay 9, and the buzzer 10 is energized to emit a warning sound. In addition, the second proximity sensor 4 detects the distance L in real time and displays the distance parameter through the smart meter 7 in real time.

[0057] When L≤L1 (L1<L0, L0=6m, the farthest detection distance of the sensor, L1=3m, the maximum braking distance of the vehicle), the vehicle controller 2 restricts the picking vehicle from moving backward or issues a braking command; when C1≤6.5V, the buzzer relay 9 does not work (C2=0), and the vehicle operates normally.

[0058] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0059] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A high-level picking forklift safety system, characterized in that: include: Vehicle controller (2); A sensor unit, the sensor unit is in signal communication with the vehicle controller (2) for transmitting a detection signal to the vehicle controller, the sensor unit comprising a tilt sensor (1), a proximity sensor, and an infrared sensor; A driving accelerator (8) is in signal communication with the vehicle controller (2) and is used to transmit a driving control signal to the vehicle controller (2); A lifting and lowering switch (13) is connected to the vehicle controller (2) by signal, and is used to transmit a lifting or lowering signal of the picking vehicle to the vehicle controller (2); The execution unit includes a picking vehicle travel component and a picking vehicle lifting component, is connected to the vehicle controller (2), receives control signals from the vehicle controller (2) and executes.

2. A high-level picking forklift safety system according to claim 1, characterized in that: The proximity sensor comprises a first proximity sensor (3) arranged at the front of the picking vehicle and a second proximity sensor (4) arranged at the rear of the picking vehicle.

3. A high-level picking forklift safety system according to claim 1, characterized in that: The infrared sensor comprises a first infrared sensor (5) arranged at the front of the picking vehicle and a second infrared sensor (6) arranged at the rear of the picking vehicle.

4. A high-level picking forklift safety system according to claim 1, characterized in that: The vehicle controller (2) is signal-connected to a display unit (7), and the display unit (7) comprises an instrument for displaying status information of the picking vehicle.

5. A high-level picking forklift safety system according to claim 1, characterized in that: The vehicle controller (2) is connected to a buzzer (10), and a relay (9) is connected between the buzzer (10) and the vehicle controller (2).

6. A high-level picking forklift safety system according to claim 1, characterized in that: The picking vehicle travel component comprises a traction motor (11) connected to the vehicle controller (2) by signal and a drive wheel assembly (12) connected to the traction motor (11) by power. The picking vehicle lifting component comprises an oil pump motor (14) connected to the vehicle controller (2) by signal, the oil pump motor is connected to a gear pump (15) by power, and the gear pump (15) is connected to a lifting cylinder (16) via an oil circuit.

7. A method for controlling the driving safety of a high-level picking forklift using the picking forklift safety system according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1, the vehicle controller (2) receives signals from the tilt sensor (1), the proximity sensor, and the infrared sensor, and processes the signals; Step 2, obtaining the current tilt angle A of the picking vehicle through the tilt sensor (1), if A≠0, executing step 3, otherwise executing step 3; Step 3: compare the current tilt angle A of the picking vehicle with the judgment thresholds A1 and A2. If A>A1, the vehicle controller (2) controls the display unit (7) to issue a "warning" signal; if A>A2, the vehicle controller (2) controls the display unit (7) to issue a "limit" signal, wherein A1 is the maximum designed climbing angle of the vehicle, and A2 is the maximum safe climbing angle of the vehicle; Step 4, determining the driving direction of the picking vehicle and the signals of the proximity sensor and the infrared sensor. When the picking vehicle is driving forward and the first proximity sensor (3) and / or the first infrared sensor (5) in front of the picking vehicle receive a detection signal, step 5 is executed; when the picking vehicle is driving backward and the second proximity sensor (4) and / or the second infrared sensor (6) in the rear of the picking vehicle receive a detection signal, step 5 is executed; Step 5: The vehicle controller (2) issues a warning via a buzzer (10), and simultaneously displays the real-time distance of the detected obstacle via a display unit (7). When the distance is less than a preset distance, the picking vehicle starts braking.

8. A method for controlling the driving safety of a high-level picking forklift according to claim 7, characterized in that: The driving accelerator (8) inputs an analog voltage signal C1 to the vehicle controller (2), and 0V<C1<12V. When 0.5V<C1<5.5V, the vehicle controller (2) controls the traction motor (11) to rotate forward, driving the drive wheel assembly (12) to rotate forward, and the picking vehicle moves forward. When 6.5V<C1<11.5V, the vehicle controller (2) controls the traction motor (11) to rotate reversely, driving the drive wheel assembly (12) to rotate backward, and the picking vehicle moves backward. When 0V<C1<0.5V, 5.5V<C1<6.5V, and 11.5V<C1<12V, the dead zone voltage is set.

9. A method for controlling the driving safety of a high-level picking forklift according to claim 7, characterized in that: The buzzer relay (9) and the buzzer (10) are connected in series with the vehicle controller (2). The loop is closed by triggering the buzzer relay (9), and the buzzer (10) is powered to emit a warning sound. The input switch signal of the buzzer (10) is C2. When C2=1, the loop is closed, and vice versa, when C2=0, the loop is disconnected. The lifting and lowering switch (13) independently inputs a lifting analog signal C4 or a lowering switch signal C3 to the vehicle controller (2). The vehicle controller (2) detects the lifting analog signal C4, and the value range of C4 is: 0V<C4<12V; When 0.5V<C4<11.5V, the gear pump (15) is driven by controlling the oil pump motor (14) to rotate, thereby realizing the oil supply to the lifting cylinder (16) and thus lifting the mast. When the vehicle controller (2) detects the descending switch signal C3=1, the mast descends, otherwise the mast does not move when C3=0.

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