Freight elevator anti-collision device and anti-collision system thereof

Abstract

An anti-collision device for a freight elevator relates to the technical field of freight elevators, is mounted at an elevator entrance of a forklift access floor, and comprises a first TOF (Time of Flight) sensor, a second TOF sensor, a third TOF sensor, a fourth TOF sensor, a fifth TOF sensor and a sixth TOF sensor, the second TOF sensor is installed at the top end of the lift car and used for measuring the position of the forklift in the lift car and the horizontal position of the most protruding part of the front end of the forklift; the elevator inner wall crash barrier is mounted on the inner wall of the car and can be controlled to move up and down; the gate device is installed on the front face of a landing door of a forklift access floor and is composed of a guard bar and a bar lifting device. And the AI camera is mounted on the wall surface of the forklift access floor and is used for shooting the face of a forklift driver. According to the method, the operation safety is improved, collision accidents can be effectively prevented, intelligent management and optimal scheduling are realized, and the logistics transportation efficiency and safety are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of freight elevators, and in particular to an anti-collision device and an anti-collision system for a freight elevator. Background Art

[0002] In the logistics and warehousing industry, forklifts are important handling tools, and their operating efficiency and safety are directly related to the efficient operation of the entire warehousing process and the safety of personnel and equipment. Especially in the scenario where a forklift is used to deliver goods to a freight elevator, due to the large size of the forklift and the possibility that the goods may block the driver's view, it is difficult for the driver to accurately judge the distance between the forklift and the elevator door and the inner wall of the elevator, thereby increasing the risk of collision. Such a collision may not only cause damage to the elevator, requiring expensive repairs, but may also pose a safety hazard to the forklift driver and other people in the elevator.

[0003] In order to deal with this problem, anti-collision monitoring light curtains are widely used as safety protection devices in existing elevator systems. Anti-collision monitoring light curtains monitor the position of forklifts by emitting and receiving infrared light. When the forklift approaches the elevator to a certain distance, the system will send out a warning signal to remind the driver to adjust the driving direction or speed of the forklift to avoid collision accidents. However, although this safety protection device has improved the safety of elevator use to a certain extent, it still has some shortcomings:

[0004] Lack of active collision avoidance measures: Existing collision avoidance monitoring light curtains mainly alert drivers through early warning signals, but if the driver fails to notice the warning or adjust the forklift in time, a collision may still occur.

[0005] Monitoring blind spot when entering the elevator at an angle: In the scenario where a forklift enters the elevator at an angle, even if the distance between the forklift position detected by the monitoring light curtain and the elevator is within a safe range, the side of the forklift may exceed the monitoring range of the light curtain, so it may still hit the elevator during the entry process.

[0006] Lack of automatic elevator calling function: It is often inconvenient for forklift drivers to manually call the elevator when operating a forklift, which not only increases the driver's operating burden, but may also affect the efficiency of the elevator.

[0007] Lack of forklift driver certification function: In a warehouse environment, it is common for non-professional forklift drivers to operate forklifts into elevators, which may not only increase the risk of collision accidents, but also cause damage to the elevator and cargo. Summary of the invention

[0008] The purpose of the present invention is to propose a comprehensive anti-collision solution for freight elevators that integrates space perception, active anti-collision intervention, intelligent process optimization and operation authority management, so as to fundamentally reduce the incidence of collision accidents.

[0009] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0010] A cargo elevator anti-collision device is installed at the elevator entrance of the floor where a forklift enters and exits, comprising:

[0011] The first TOF sensor is installed on the wall above the door of the floor where the forklift enters and exits, and is used to measure the position and offset angle of the forklift;

[0012] The second TOF sensor is installed on the top of the car to measure the horizontal position of the forklift's position in the car and the most protruding part of the forklift's front end;

[0013] The elevator inner wall anti-collision barrier is installed on the inner wall of the car and can be controlled to move up and down;

[0014] The gate device is installed in front of the landing door where forklifts enter and exit the floor, and consists of a barrier and a lifting device;

[0015] The AI ​​camera is installed on the wall of the forklift entry and exit floor to capture the forklift driver’s face.

[0016] Furthermore, the first TOF sensor adopts a 30°×90° asymmetric field of view design, which acquires forklift movement trajectory data at a sampling frequency of 15 Hz, and a built-in inertial measurement unit compensates for building vibration errors.

[0017] Furthermore, the elevator inner wall anti-collision barrier includes:

[0018] The aluminum alloy frame body is driven up and down by a drive motor, and a honeycomb energy-absorbing structure is embedded in the frame;

[0019] The polyurethane buffer layer covering the surface of the aluminum alloy frame has a Shore hardness of 60A-80A;

[0020] A distributed pressure sensor network is arranged on the surface of the aluminum alloy frame body, comprising at least three groups of transversely arranged piezoresistive sensor strips.

[0021] An anti-collision system applied to the anti-collision device of a freight elevator, comprising:

[0022] Face recognition module, used for authentication of permissions based on the face sent back by the AI ​​camera;

[0023] The gate control module controls the gate to lift the lever and release the person according to the permission authentication result of the face recognition module;

[0024] Elevator control module, used to call the freight elevator and control the opening / closing of the elevator floor door and car door;

[0025] The crash barrier control module controls the up and down movement of the crash barrier according to the horizontal position of the most protruding part of the front end of the forklift measured by the second TOF sensor;

[0026] The offset angle calculation module calculates the offset angle of the forklift relative to the front of the landing door according to the measurement data of the first TOF sensor.

[0027] Furthermore, it also includes a voice prompt module, which is used to provide voice guidance or reminders to the forklift driver in key operation links such as the forklift approaching the elevator entrance, passing the authority verification, the gate opening, and the elevator door opening and closing.

[0028] Furthermore, the first TOF sensor and the second TOF sensor both have an environmental adaptability adjustment function, which can automatically adjust the measurement parameters according to factors such as light conditions and object surface characteristics.

[0029] Furthermore, it also includes a remote monitoring and management platform, which can receive and analyze data from various sensors in real time, remotely monitor the working status of the elevator anti-collision device, and realize fault warning, data analysis and optimized scheduling functions.

[0030] Furthermore, after the offset angle calculation module calculates the offset angle of the forklift relative to the front of the landing door, if the offset angle exceeds a preset safety angle range, the system sends an alarm signal to remind the forklift driver to adjust the position of the forklift.

[0031] Furthermore, a hierarchical alarm module is also included, and the hierarchical alarm module includes:

[0032] Level 1 warning: When the forklift deviates by more than 5°, an audible and visual warning will be triggered;

[0033] Level 2 warning: prompt emergency braking when the estimated collision time is less than 3 seconds;

[0034] Level 3 warning: When structural damage is detected, the elevator is locked and a remote alarm is sent.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] The present invention proposes a cargo elevator anti-collision device and an anti-collision system that integrates a first and a second TOF sensor, an elevator inner wall anti-collision barrier, a gate device, and an AI camera. The system can accurately measure the position and offset angle of the forklift, and realize functions such as authority authentication, gate control, elevator calling and door control, dynamic adjustment of the anti-collision barrier, and offset warning. Through environmental adaptability adjustment, remote monitoring and management platform, and hierarchical alarm module, the system not only improves operational safety, but also effectively prevents collision accidents, while realizing intelligent management and optimized scheduling, significantly improving logistics and transportation efficiency and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0038] Figure 1 It is a schematic diagram of the anti-collision device outside the door of the present invention.

[0039] Figure 2 It is a schematic diagram of the anti-collision device in the car of the present invention.

[0040] Figure 3 Schematic diagram of the anti-collision system of the present invention. DETAILED DESCRIPTION

[0041] The technical solutions in the embodiments of the present invention are described clearly and completely below. 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.

[0042] In the description of the present invention, it is necessary to understand that the terms "upper", "lower", "front", "back", "vertical", "horizontal", "inside", "outside", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0043] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0044] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being "above", "above" or "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below", "below" or "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0045] like Figure 1-3 As shown, a cargo elevator anti-collision device is installed at the elevator entrance of the floor where a forklift enters and exits, comprising:

[0046] The first TOF sensor 1 is installed on the wall above the door of the floor where the forklift enters and exits, and is used to measure the position and offset angle of the forklift;

[0047] The second TOF sensor 2 is installed on the top of the car and is used to measure the horizontal position of the forklift's position in the car and the most protruding part of the forklift's front end;

[0048] The elevator inner wall anti-collision barrier 3 is installed on the inner wall of the car and can be controlled to move up and down;

[0049] The gate device 4 is installed in front of the landing door for forklifts to enter and exit the floor, and is composed of a barrier and a lifting device;

[0050] AI camera 5 is installed on the wall of the forklift entrance and exit floor to capture the face of the forklift driver.

[0051] Specifically, as shown in the figure, the first TOF sensor adopts a 30°×90° asymmetric field of view design, which acquires the forklift's travel trajectory data at a sampling frequency of 15Hz, and a built-in inertial measurement unit compensates for building vibration errors.

[0052] Specifically, as shown in the figure, the elevator inner wall anti-collision barrier includes:

[0053] The aluminum alloy frame body is driven up and down by a drive motor, and a honeycomb energy-absorbing structure is embedded in the frame;

[0054] The polyurethane buffer layer covering the surface of the aluminum alloy frame has a Shore hardness of 60A-80A;

[0055] A distributed pressure sensor network is arranged on the surface of the aluminum alloy frame body, comprising at least three groups of transversely arranged piezoresistive sensor strips.

[0056] The drive motor adopts a closed-loop servo control system, and the vertical lifting of the crash barrier is realized through a worm gear transmission mechanism (speed range 0.1-0.5m / s, positioning accuracy ±2mm). Based on the three-dimensional coordinates of the protruding part of the forklift cargo fed back in real time by the second TOF sensor, the system automatically calculates the target height of the crash barrier H=H0+ΔH, where H0 is the reference height of the inner wall of the car, and ΔH is the dynamic compensation value of the protruding amount of the cargo (ΔH=K×L, L is the horizontal length of the protruding cargo, and K is the safety factor 0.6-0.8).

[0057] The aluminum alloy frame is embedded with a hexagonal aluminum honeycomb core (wall thickness 0.2mm, pore diameter 5mm), which absorbs impact energy through plastic deformation. When the forklift hits the crash barrier from the side (impact force F ≥ 500N), the honeycomb structure undergoes progressive collapse (deformation δ = √ (F / E·A), E is the material elastic modulus, A is the contact area), converting the collision kinetic energy into structural deformation energy, reducing the peak impact force by 40%-60%.

[0058] The polyurethane layer (thickness 15-20mm) adopts a gradient density design, with a surface hardness of 80A to provide a rigid contact surface, and an inner hardness of 60A to enhance energy absorption. When the forklift contacts the crash barrier at a speed v, the buffer layer produces a time-varying damping effect: F(t) = C·v(t)^α+K·x(t)^β, where C is the viscous damping coefficient (C = 120-150N·s / m), K is the elastic stiffness (K = 800-1000N / mm), α and β are nonlinear exponents (α = 1.2, β = 1.5), and the impact force is gently attenuated by adjusting the material ratio. The polyurethane surface is processed with 3D raised patterns (height 2-3mm, spacing 10mm). When the forklift collides with the guardrail, the patterns generate a directional friction torque M = μ·F·r (μ = 0.4-0.6, r is the contact radius), forcing the forklift to self-correct (typical correction angle 3°-5°).

[0059] The piezoresistive sensor strips are arranged horizontally with a spacing of 200 mm. Each set of sensor strips contains 32 independent sensing units (resolution 10N, sampling frequency 100 Hz). The system identifies the collision area through the spatial pressure distribution matrix P (x, y):

[0060] Area A (height H1-H2): When continuous pressure > 200N and duration > 0.5s is detected, the height of the crash barrier is fine-tuned (stepper motor action Δh = ±50mm);

[0061] Area B (height H3-H4): When the transient pressure peak value > 800N is detected, the car emergency brake is activated (deceleration ≥ 2m / s 2 ) and the gate is locked;

[0062] Area C (height H5-H6): When the pressure gradient dp / dt>500N / s, the buzzer directional alarm is activated (sound pressure level 90dB@1m).

[0063] When a forklift enters the car, the crash barrier performs the following sequence of actions:

[0064] Pre-positioning stage: according to the cargo contour scanning result of TOF sensor 2, the anti-collision barrier is raised to the predicted protection height;

[0065] Dynamic adjustment stage: real-time comparison of pressure sensor data with preset safety thresholds, and adjustment of the guardrail position through a PID controller (Kp = 2.5, Ki = 0.1, Kd = 0.8);

[0066] Impact absorption stage: When substantial contact occurs, the honeycomb structure and the polyurethane layer work together to limit the impact energy within a safe threshold (≤1200J);

[0067] Reset stage: After the forklift stops, the anti-collision barrier drops to the reference position, the pressure sensor data is reset, and the next working cycle is prepared.

[0068] like Figure 3 As shown, an anti-collision system applied to the anti-collision device of the freight elevator comprises:

[0069] Face recognition module, used for authentication of permissions based on the face sent back by the AI ​​camera;

[0070] The gate control module controls the gate to lift the lever and release the person according to the permission authentication result of the face recognition module;

[0071] Elevator control module, used to call the freight elevator and control the opening / closing of the elevator floor door and car door;

[0072] The crash barrier control module controls the up and down movement of the crash barrier according to the horizontal position of the most protruding part of the front end of the forklift measured by the second TOF sensor;

[0073] The offset angle calculation module calculates the offset angle of the forklift relative to the front of the landing door according to the measurement data of the first TOF sensor.

[0074] Specifically, it also includes a voice prompt module, which is used to provide voice guidance or reminders to the forklift driver in key operation links such as the forklift approaching the elevator entrance, passing the authority verification, the gate opening, and the elevator door opening and closing.

[0075] Specifically, the first TOF sensor and the second TOF sensor both have an environmental adaptability adjustment function, which can automatically adjust the measurement parameters according to factors such as light conditions and object surface characteristics.

[0076] Specifically, it also includes a remote monitoring and management platform, which can receive and analyze data from various sensors in real time, remotely monitor the working status of the elevator anti-collision device, and realize fault warning, data analysis and optimized scheduling functions.

[0077] Specifically, after the offset angle calculation module calculates the offset angle of the forklift relative to the front of the landing door, if the offset angle exceeds a preset safety angle range, the system sends an alarm signal to remind the forklift driver to adjust the position of the forklift.

[0078] Specifically, it also includes a hierarchical alarm module, which includes:

[0079] Level 1 warning: When the forklift deviates by more than 5°, an audible and visual warning will be triggered;

[0080] Level 2 warning: prompt emergency braking when the estimated collision time is less than 3 seconds;

[0081] Level 3 warning: When structural damage is detected, the elevator is locked and a remote alarm is sent.

[0082] Specifically, the specific implementation process of the present invention is:

[0083] When a forklift (including the cargo it carries) enters the elevator waiting area, the entire cargo elevator anti-collision system begins to operate. Its workflow is divided into the following steps:

[0084] Distance monitoring and early warning: First, the first TOF sensor accurately measures the distance between the most protruding part of the forklift and the vertical plane of the gate railing. Once the distance is less than or equal to the preset safety threshold, the system will immediately trigger an early warning signal to prompt the forklift driver to stop by voice or other effective means to ensure a safe distance.

[0085] Identity verification and permission check: Next, the system verifies the identity of the person passing through the gate by entering information, including whether he is a forklift driver and whether he has the permission to pass through the gate. At the same time, the AI ​​camera performs facial recognition on the forklift driver and compares the recognition result with the facial recognition module in the system to verify the identity information. If the information does not match, the system will issue an early warning to remind the operator that he does not meet the professional requirements or has insufficient authority.

[0086] Position correction and collision warning: If the identity information is verified, the first TOF sensor will further detect the distance from the front of the forklift to the landing door. If the distances on both sides are not equal, it means that the forklift is not facing the elevator landing door. At this time, the system will accurately calculate the offset angle of the forklift through the offset angle calculation module, and evaluate whether it may collide with the landing door or the inner wall of the side of the car if it moves forward at this angle. If there is a risk of collision, the system will issue a warning to prompt the driver to adjust the position of the forklift.

[0087] Elevator call and door control linkage: When the identity information is verified and the forklift is in the correct position and there is no collision risk, the system will link the elevator control module to call the elevator to the floor where the forklift is located. After the elevator arrives, the control module will automatically open the floor door and car door, and synchronously control the gate lift bar to allow the forklift to enter.

[0088] Running time calculation and door opening time adjustment: Combined with the distance between the forklift and the landing door, the length and speed of the forklift measured by the first TOF sensor, the system uses the speed measurement module to accurately calculate the time required for the forklift to fully enter the car. Based on this, the elevator control module will adjust the time the freight elevator stays open to ensure that there is enough time for the forklift to enter safely.

[0089] Dynamic adjustment of the crash barrier: After the landing door and the car door are opened, the second TOF sensor will measure the vertical position of the most protruding part of the front end of the forklift. Based on this information, the system will link the crash barrier control module and dynamically adjust the crash barrier on the inner wall of the car to the horizontal position of the protruding part of the forklift, effectively preventing the forklift from colliding with the inner wall after entering the car.

[0090] Special treatment for single-person traffic: For single-person traffic, the AI ​​camera will automatically identify and trigger the gate's automatic lift function. At this time, the cargo elevator's anti-collision device and system will not be involved in the operation, ensuring convenient pedestrian traffic.

[0091] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

[0092] 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 cargo elevator anti-collision device, installed at the elevator entrance of the floor where the forklift enters and exits, characterized in that: include: The first TOF sensor is installed on the wall above the door of the floor where the forklift enters and exits, and is used to measure the position and offset angle of the forklift; The second TOF sensor is installed on the top of the car to measure the horizontal position of the forklift's position in the car and the most protruding part of the forklift's front end; The elevator inner wall anti-collision barrier is installed on the inner wall of the car and can be controlled to move up and down; The gate device is installed in front of the landing door where forklifts enter and exit the floor, and consists of a barrier and a lifting device; The AI ​​camera is installed on the wall of the forklift entry and exit floor to capture the forklift driver’s face.

2. The anti-collision device for a freight elevator according to claim 1, characterized in that: The first TOF sensor adopts a 30°×90° asymmetric field of view design. It acquires forklift movement trajectory data at a sampling frequency of 15Hz, and the built-in inertial measurement unit compensates for building vibration errors.

3. The anti-collision device for a freight elevator according to claim 1, characterized in that: The elevator inner wall anti-collision fence comprises: The aluminum alloy frame body is driven up and down by a drive motor, and a honeycomb energy-absorbing structure is embedded in the frame; The polyurethane buffer layer covering the surface of the aluminum alloy frame has a Shore hardness of 60A-80A; A distributed pressure sensor network is arranged on the surface of the aluminum alloy frame body, comprising at least three groups of transversely arranged piezoresistive sensor strips.

4. An anti-collision system applied to the anti-collision device of a freight elevator according to claim 1, characterized in that: include: Face recognition module, used for authentication of permissions based on the face sent back by the AI ​​camera; The gate control module controls the gate to lift the lever and release the person according to the permission authentication result of the face recognition module; Elevator control module, used to call the freight elevator and control the opening / closing of the elevator floor door and car door; The crash barrier control module controls the up and down movement of the crash barrier according to the horizontal position of the most protruding part of the front end of the forklift measured by the second TOF sensor; The offset angle calculation module calculates the offset angle of the forklift relative to the front of the landing door according to the measurement data of the first TOF sensor.

5. The anti-collision system for a freight elevator according to claim 4, characterized in that: It also includes a voice prompt module, which is used to provide voice guidance or reminders to the forklift driver during key operations such as the forklift approaching the elevator entrance, passing the authority verification, the gate opening, and the elevator door opening and closing.

6. The anti-collision system for a freight elevator according to claim 4, characterized in that: The first TOF sensor and the second TOF sensor both have an environmental adaptability adjustment function and can automatically adjust measurement parameters according to factors such as light conditions and object surface characteristics.

7. The anti-collision system for a freight elevator according to claim 4, characterized in that: It also includes a remote monitoring and management platform, which can receive and analyze data from various sensors in real time, remotely monitor the working status of the elevator anti-collision device, and realize fault warning, data analysis and optimized scheduling functions.

8. The anti-collision system for a freight elevator according to claim 4, characterized in that: After the offset angle calculation module calculates the offset angle of the forklift relative to the front of the landing door, if the offset angle exceeds a preset safety angle range, the system sends an alarm signal to remind the forklift driver to adjust the position of the forklift.

9. The anti-collision system for a freight elevator according to claim 4, characterized in that: It also includes a hierarchical alarm module, which includes: Level 1 warning: When the forklift deviates by more than 5°, an audible and visual warning will be triggered; Level 2 warning: prompt emergency braking when the estimated collision time is less than 3 seconds; Level 3 warning: When structural damage is detected, the elevator is locked and a remote alarm is sent.

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