Anti-collision device for freight elevator and anti-collision system thereof

Abstract

The application relates to a collision-preventing device for a cargo elevator, which is installed at an elevator entrance of a floor where a forklift truck enters and exits, and comprises a first TOF sensor, which is installed on a wall above a layer door of the floor where the forklift truck enters and exits, and is used for measuring the position and deviation angle of the forklift truck; a second TOF sensor, which is installed at the top end of a car, and is used for measuring the position of the forklift truck in the car and the horizontal position of the most protruding part at the front end of the forklift truck; an elevator inner wall collision-preventing fence, which is installed on the inner wall of the car and can be controlled to move up and down; a gate device, which is installed in front of the layer door of the floor where the forklift truck enters and exits, and is composed of a blocking rod and a lifting rod device; and an AI camera, which is installed on the wall of the floor where the forklift truck enters and exits, and is used for shooting the face of a forklift truck driver. The application not only improves the operation safety, but also effectively prevents collision accidents, simultaneously realizes intelligent management and optimized scheduling, and significantly improves the logistics transportation efficiency and safety.

Description

Technical Field

[0001] This invention relates to the field of freight elevator technology, and specifically to a freight elevator anti-collision device and its anti-collision system. Background Technology

[0002] In the logistics and warehousing industry, forklifts are crucial material handling tools, and their operational efficiency and safety directly impact the efficient operation of the entire warehousing process and the safety of personnel and equipment. Especially in scenarios where forklifts are used to transport goods into freight elevators, the large size of forklifts and the potential obstruction of the driver's view by the cargo can make it difficult for the driver to accurately judge the distance between the forklift and the elevator landing doors and car walls, thus increasing the risk of collisions. Such collisions can not only damage the elevator, requiring costly repairs, but also pose safety hazards to the forklift driver and other personnel inside the elevator.

[0003] To address this issue, existing elevator systems commonly employ collision-prevention light curtains as a safety device. These curtains monitor the forklift's position by emitting and receiving infrared light. When the forklift approaches the elevator to a certain distance, the system issues a warning signal, alerting the driver to adjust the forklift's direction or speed to avoid a collision. However, while this safety device improves elevator safety to some extent, it still has some shortcomings:

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

[0005] Blind spots in monitoring when a forklift enters an elevator at an angle: In scenarios where a forklift enters an elevator at an angle, even if the distance between the forklift and the elevator detected by the monitoring light curtain is within a safe range, the side of the forklift may still be outside the monitoring range of the light curtain, so it may still collide with the elevator during the entry process.

[0006] Lack of automatic elevator calling function: Forklift drivers often find it inconvenient to manually call the elevator while operating the forklift, which not only increases the driver's workload but may also affect the elevator's efficiency.

[0007] Lack of forklift driver certification: In warehouse environments, it is common for non-professional forklift drivers to operate forklifts into elevators, which may not only increase the risk of collisions but also damage elevators and goods. Summary of the Invention

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

[0009] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0010] A freight elevator anti-collision device, installed at the elevator entrance of a floor where a forklift enters or exits, includes:

[0011] The first TOF sensor is installed on the wall above the floor door where forklifts enter and exit, and is used to measure the position and offset angle of the forklifts.

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

[0013] The elevator interior wall anti-collision railing is installed on the interior wall of the elevator car and can be controlled to move up and down.

[0014] The turnstile device is installed in front of the floor doors where forklifts enter and exit the floors, and consists of a barrier and a lifting mechanism.

[0015] AI cameras are installed on the walls of the floors where forklifts enter and exit, and are used to capture the faces of forklift drivers.

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

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

[0018] The main body of the aluminum alloy frame is driven to lift by a drive motor, and the frame is embedded with a honeycomb energy-absorbing structure;

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

[0020] The surface of the aluminum alloy frame is provided with a distributed pressure sensor network, which includes at least three sets of piezoresistive sensor strips arranged laterally.

[0021] A collision avoidance system applied to the freight elevator collision avoidance device includes:

[0022] The facial recognition module is used for authorization authentication using the face transmitted back by the AI ​​camera;

[0023] The gate control module controls the gate to raise and allow passage based on the authentication result of the facial recognition module.

[0024] The elevator control module is used to summon the freight elevator and control the opening / closing of the elevator landing doors and car doors;

[0025] The crash barrier control module controls the up and down movement of the crash barrier based on the horizontal position of the most protruding part at the front 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 door based on the measurement data of the first TOF sensor.

[0027] Furthermore, it also includes a voice prompt module, which provides voice guidance or reminders to the forklift driver during key operational steps such as the forklift approaching the elevator entrance, authorization verification being passed, the gate opening, and the elevator door opening and closing.

[0028] Furthermore, both the first and second TOF sensors possess environmental adaptability adjustment capabilities, enabling them to automatically adjust measurement parameters based on factors such as lighting 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 elevator anti-collision devices, 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 door, if the offset angle exceeds the preset safe angle range, the system issues an alarm signal to remind the forklift driver to adjust the forklift position.

[0031] Furthermore, it also includes a tiered alarm module, which includes:

[0032] Level 1 warning: An audible and visual alert is triggered when the forklift's deviation angle exceeds 5°;

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

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

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

[0036] This invention proposes a freight elevator anti-collision device and system integrating first and second TOF sensors, elevator inner wall anti-collision barriers, turnstiles, and an AI camera. This system can accurately measure the position and offset angle of forklifts, enabling functions such as access authentication, turnstile control, elevator calling and door control, dynamic adjustment of the anti-collision barriers, and offset warning. Through environmental adaptability adjustments, a remote monitoring and management platform, and a tiered alarm module, the system not only improves operational safety but also effectively prevents collision accidents. Simultaneously, it achieves intelligent management and optimized scheduling, significantly improving logistics transportation efficiency and safety. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

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

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

[0040] Figure 3 This is a schematic diagram of the anti-collision system of the present invention. Detailed Implementation

[0041] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0043] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0044] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first and second features are in direct contact, or that they are in indirect contact through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

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

[0046] The first TOF sensor 1 is installed on the wall above the floor door where the forklift enters and exits the floor, 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 position of the forklift in the car and the horizontal position of the most protruding part of the front of the forklift.

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

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

[0050] AI Camera 5 is installed on the wall of the floor where forklifts enter and exit, and is used 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 forklift trajectory data at a sampling frequency of 15Hz, and has a built-in inertial measurement unit to compensate for building vibration errors.

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

[0053] The main body of the aluminum alloy frame is driven to lift by a drive motor, and the frame is embedded with a honeycomb energy-absorbing structure;

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

[0055] The surface of the aluminum alloy frame is provided with a distributed pressure sensor network, which includes at least three sets of piezoresistive sensor strips arranged laterally.

[0056] The drive motor employs a closed-loop servo control system, using a worm gear transmission mechanism to achieve vertical lifting of the crash barrier (speed range 0.1-0.5 m / s, positioning accuracy ±2 mm). Based on the real-time feedback of the three-dimensional coordinates of the protruding part of the forklift cargo from 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 cargo protrusion (ΔH = K × L, where L is the horizontal length of the cargo protrusion, and K is a safety factor of 0.6-0.8).

[0057] The aluminum alloy frame is embedded with a hexagonal honeycomb aluminum core (0.2mm wall thickness, 5mm aperture), which absorbs impact energy through plastic deformation. When a forklift impacts the guardrail from the side (impact force F≥500N), the honeycomb structure undergoes progressive collapse (deformation δ=√(F / E·A), where E is the elastic modulus of the material and 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 (15-20mm thick) features a gradient density design, with an 80A surface hardness providing a rigid contact surface and an 60A inner layer enhancing energy absorption. When a forklift contacts the crash barrier at speed v, the buffer layer generates 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), and α and β are nonlinear exponents (α=1.2, β=1.5). The impact force is gradually attenuated by adjusting the material ratio. The polyurethane surface is processed with 3D raised textures (2-3mm high, 10mm spacing). When the forklift collides with the guardrail, the textures generate a directional friction torque M = μ·F·r (μ = 0.4-0.6, r is the contact radius), which forces the forklift to produce a self-correcting deflection (typical correction angle 3°-5°).

[0059] Piezoresistive sensor strips are arranged laterally with a spacing of 200 mm. Each strip contains 32 independent sensing units (10N resolution, 100Hz sampling frequency). The system identifies the collision region using the spatial pressure distribution matrix P(x,y).

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

[0061] Zone B (Height H3-H4): When a transient pressure peak > 800N is detected, activate the car emergency brake (deceleration ≥ 2m / s²). 2 And the gate will lock in conjunction with it;

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

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

[0064] Pre-positioning stage: Based on the cargo outline scanning results from TOF sensor 2, the crash barrier is raised to the predicted protection height;

[0065] Dynamic adjustment phase: Real-time comparison of pressure sensor data with preset safety thresholds, and adjustment of the crash barrier position via PID controller (Kp=2.5, Ki=0.1, Kd=0.8);

[0066] Impact absorption phase: 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 phase: After the forklift comes to a complete stop, the crash barrier descends to the reference position, the pressure sensor data is reset to zero, and the system is ready for the next work cycle.

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

[0069] The facial recognition module is used for authorization authentication using the face transmitted back by the AI ​​camera;

[0070] The gate control module controls the gate to raise and allow passage based on the authentication result of the facial recognition module.

[0071] The elevator control module is used to summon the freight elevator and control the opening / closing of the elevator landing doors and car doors;

[0072] The crash barrier control module controls the up and down movement of the crash barrier based on the horizontal position of the most protruding part at the front 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 door based on the measurement data of the first TOF sensor.

[0074] Specifically, it also includes a voice prompt module, which provides voice guidance or reminders to forklift drivers during key operations such as forklift approaching the elevator entrance, authorization verification, gate opening, and elevator door opening and closing.

[0075] Specifically, both the first and second TOF sensors have environmental adaptability adjustment functions, which can automatically adjust the measurement parameters according to factors such as lighting 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 elevator anti-collision devices, 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 door, if the offset angle exceeds the preset safe angle range, the system issues an alarm signal to remind the forklift driver to adjust the position of the forklift.

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

[0079] Level 1 warning: An audible and visual alert is triggered when the forklift's deviation angle exceeds 5°;

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

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

[0082] Specifically, the specific implementation process of this invention is as follows:

[0083] When a forklift (including its cargo) enters the waiting area, the entire freight elevator's anti-collision system activates. Its workflow is detailed in 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 barrier. Once this distance is less than or equal to a preset safety threshold, the system will immediately trigger an early warning signal, prompting the forklift driver to stop via voice or other effective means to ensure a safe distance.

[0085] Identity Verification and Access Control: Next, the system verifies the identity of the person passing through by checking the entered information, including whether they are a forklift driver and whether they have the authority to pass through the gate. Simultaneously, an AI camera performs facial recognition on the forklift driver, comparing the result with the facial authentication module in the system to verify their identity. If the information does not match, the system will issue a warning, reminding the operator that they do not meet the professional requirements or have insufficient permissions.

[0086] Position Correction and Collision Warning: If the identity information verification is successful, the first TOF sensor will further detect the distance from both sides of the forklift's front end to the landing door. If the distances on both sides are unequal, it means that the forklift is not directly facing the elevator landing door. At this time, the system will use the offset angle calculation module to accurately calculate the forklift's offset angle and assess whether moving at this angle may result in a collision with the landing door or the inner wall of the elevator car side. If there is a collision risk, the system will issue a warning, prompting the driver to adjust the forklift's position.

[0087] Elevator call and door control linkage: Once the identity information is verified and the forklift is in the correct position with no risk of collision, the system will link with the elevator control module to call the elevator to the floor where the forklift is located. Upon arrival, the control module will automatically open the landing door and car door, and simultaneously control the turnstile to raise, allowing the forklift to enter.

[0088] Running time calculation and door opening time adjustment: Combining the distance between the forklift and the landing door, the forklift length, and its speed measured by the first TOF sensor, the system accurately calculates the time required for the forklift to fully enter the elevator car through the speed measurement module. Based on this, the elevator control module adjusts the elevator's dwell time for door opening to ensure sufficient time for the forklift to enter safely.

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

[0090] Special handling for single-person passage: In the event of a single person passing through, the AI ​​camera will automatically identify and trigger the automatic gate opening function. At this time, the freight elevator's anti-collision device and system will not operate, ensuring convenient pedestrian passage.

[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 principles of the present invention should be included within the protection scope of the present invention.

[0092] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A freight elevator anti-collision device, installed at the elevator entrance of a floor where a forklift enters or exits, characterized in that, include: The first TOF sensor is installed on the wall above the floor door where forklifts enter and exit, and is used to measure the position and offset angle of the forklifts. The second TOF sensor is installed on the top of the car and is used to measure the position of the forklift in the car and the horizontal position of the most protruding part of the forklift's front end. The elevator interior wall anti-collision railing is installed on the interior wall of the elevator car and can be controlled to move up and down. The turnstile device is installed in front of the floor doors where forklifts enter and exit the floors, and consists of a barrier and a lifting mechanism. AI cameras are installed on the walls of the floors where forklifts enter and exit, and are used to capture the faces of forklift drivers. The system uses the measurement information from the second TOF sensor to link with the anti-collision barrier control module, dynamically adjusting the anti-collision barriers on the inner wall of the car to a horizontal position at the protruding part of the forklift.

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

3. The anti-collision device for freight elevators according to claim 1, characterized in that, The elevator inner wall anti-collision rails include: The main body of the aluminum alloy frame is driven to lift by a drive motor, and the frame is embedded with a honeycomb energy-absorbing structure; The polyurethane buffer layer covering the surface of the aluminum alloy frame has a Shore hardness of 60A-80A. The surface of the aluminum alloy frame is provided with a distributed pressure sensor network, which includes at least three sets of piezoresistive sensor strips arranged laterally.

4. A collision avoidance system applied to the anti-collision device of the freight elevator as described in claim 1, characterized in that, include: The facial recognition module is used for authorization authentication using the face transmitted back by the AI ​​camera; The gate control module controls the gate to raise and allow passage based on the authentication result of the facial recognition module. The elevator control module is used to summon the freight elevator and control the opening / closing of the elevator landing doors and car doors; The crash barrier control module controls the up and down movement of the crash barrier based on the horizontal position of the most protruding part at the front 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 door based on the measurement data of the first TOF sensor.

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

6. The freight elevator anti-collision system according to claim 4, characterized in that, Both the first and second TOF sensors have environmental adaptability adjustment functions, which can automatically adjust the measurement parameters according to factors such as lighting conditions and object surface characteristics.

7. The freight elevator anti-collision system 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 elevator anti-collision devices, and realize fault warning, data analysis and optimized scheduling functions.

8. The freight elevator anti-collision system 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 door, if the offset angle exceeds the preset safe angle range, the system will issue an alarm signal to remind the forklift driver to adjust the position of the forklift.

9. The freight elevator anti-collision system according to claim 4, characterized in that, It also includes a tiered alarm module, which includes: Level 1 warning: An audible and visual alert is triggered when the forklift's deviation angle exceeds 5°; Level 2 warning: Emergency braking is prompted when the estimated collision time is less than 3 seconds; Level 3 warning: When structural damage is detected, the elevator will be locked and a remote alarm will be sent.

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