Safety protection system and method for counterbalanced fork lift truck

Abstract

This invention discloses a safety protection system and method for a counterbalance forklift, belonging to the technical field of counterbalance forklifts. The safety protection system includes a first camera located at one end of the overhead guard, a second camera located at the other end of the overhead guard, a display control unit located in the cab and electrically connected to the first and second cameras, a throttle speed limiter unit and a vehicle control unit located in the floor and electrically connected to each other, a radar located on one side of the counterweight and electrically connected to the display control unit, and an accelerator pedal located at the bottom of the cab and connected to the vehicle control unit. The display control unit is equipped with an alarm module and is electrically connected to the throttle speed limiter unit. This invention achieves full-scene safety protection by setting three levels of protection zones in a tiered manner, matching graded warning, active speed limit, and forced stop step-by-step protection logic, while avoiding operation interruption caused by over-protection, perfectly adapting to the complex operating conditions of forklifts.

Description

Technical Field

[0001] This invention belongs to the field of counterbalance forklift technology, and particularly relates to a safety protection system and method for a counterbalance forklift. Background Technology

[0002] Forklifts, as core material handling equipment in industrial sites, are widely used in warehousing and logistics, manufacturing, and port terminals. Their operating environment is generally characterized by densely stacked goods and dynamic interactions between vehicles and pedestrians, resulting in a high concentration of various uncontrollable influencing factors. At the same time, the mast system, overhead guard, counterbalance, and other structures inherent to forklifts can easily limit the driver's field of vision, creating numerous blind spots. This leads to frequent safety accidents such as collisions and crushing during forklift operations, causing serious personal injury and significant property damage.

[0003] In existing technologies, conventional safety protection solutions for forklifts in the industry mostly adopt a single radar warning or single pedestrian visual recognition approach. Among them, the solution that only uses pedestrian visual recognition cannot detect non-human obstacles around the forklift operation, and the protection coverage is obviously insufficient, resulting in unsatisfactory safety protection effect. The solution that only uses radar warning is prone to false alarms in confined space operation scenarios, triggering abnormal stops and affecting operation efficiency, and at the same time, it cannot provide accurate and effective targeted protection for pedestrians. More importantly, most of the above-mentioned existing solutions only have warning and prompt functions, and do not have active safety control capabilities such as active speed limiting and forced stopping. They cannot fundamentally avoid the safety risks caused by driver negligence and misoperation, and cannot meet the high-level safety protection requirements of complex forklift operation scenarios. In summary, there is an urgent need for a safety protection system and method for counterbalance forklifts. Summary of the Invention

[0004] To address some or all of the technical problems existing in the prior art, the present invention provides a safety protection system and method for counterbalanced forklifts.

[0005] In one aspect of the present invention, a safety protection system for a counterbalance forklift is provided. The forklift has a top guard, a bottom plate, and a counterweight at the rear. The cab is located between the top guard and the bottom plate. The safety protection system includes a first camera at one end of the top guard, a second camera at the other end of the top guard, a display control unit located in the cab and electrically connected to the first and second cameras, a throttle speed limiter and a vehicle control unit electrically connected to each other within the bottom plate, a radar located on one side of the counterweight and electrically connected to the display control unit, and an accelerator pedal located at the bottom of the cab and connected to the vehicle control unit. The display control unit has an alarm module and is electrically connected to the throttle speed limiter.

[0006] Furthermore, in the safety protection system of the aforementioned counterbalance forklift, the alarm module is a buzzer.

[0007] In another aspect of the present invention, a safety protection method for a counterbalance forklift is also provided, comprising: Step 1: When the forklift is working, the first camera and the second camera respectively identify the markers in front of and behind the forklift. The camera areas of the first camera and the second camera each include three areas set in a tiered manner: a first area away from the forklift, a second area, and a third area close to the forklift. Step 2: When the marker enters the first area, the first camera and the second camera send corresponding data to the display control unit. The display control unit displays the images captured by the first camera and the second camera, and the alarm module issues a first sound warning. At the same time, the right side of the display screen of the display control unit displays the warning sign corresponding to the marker, and the forklift continues to operate normally. Step 3: When the marker enters the second area, the first camera and the second camera send corresponding data to the display control unit. The display control unit displays the images captured by the first camera and the second camera, and the alarm module issues a second audible warning. At the same time, the right side of the display screen of the display control unit displays the warning sign corresponding to the marker. Simultaneously, the display control unit outputs a signal to the throttle speed limiting unit, and the throttle speed limiting unit reduces the throttle signal transmitted from the accelerator pedal to the vehicle control unit, so that the forklift travels at a preset safe speed. Step 4: When the marker enters the third area, the first camera and the second camera send corresponding data to the display control unit. The display control unit displays the images captured by the first camera and the second camera, and the alarm module issues a third sound warning. At the same time, the right side of the display screen of the display control unit displays the warning sign corresponding to the marker. Simultaneously, the display control unit outputs a signal to the throttle speed limiting unit, and the throttle speed limiting unit cuts off the throttle signal transmitted from the accelerator pedal to the vehicle control unit. The forklift decelerates until it comes to a complete stop.

[0008] Furthermore, in the aforementioned safety protection method for the counterbalance forklift, when the forklift is reversing, the display control unit displays the image captured by the second camera. Simultaneously, the radar is activated to detect obstacles behind the counterweight. When the radar detects that the obstacle is more than a preset safe distance from the forklift, it transmits a signal to the display control unit, and the alarm module issues a second audible warning. Simultaneously, the display control unit outputs a signal to the throttle speed limiting unit, which reduces the throttle signal transmitted from the accelerator pedal to the vehicle control unit. The forklift travels at a preset safe speed. When the forklift detects that the obstacle is less than the preset safe distance from the forklift, the alarm module issues a third audible warning, and the display control unit outputs a signal to the throttle speed limiting unit, which cuts off the throttle signal transmitted from the accelerator pedal to the vehicle control unit. The forklift decelerates until it comes to a complete stop.

[0009] Furthermore, in the above-mentioned safety protection method for counterbalance forklifts, the first area is a passage area displayed in green, the second area is a warning area displayed in yellow, and the third area is a warning area displayed in red.

[0010] Furthermore, in the above-mentioned safety protection method for counterbalance forklifts, the first sound is a beeping sound with an interval of 1-1.5 seconds, the second sound is a beeping sound with an interval of 0.3-0.7 seconds, and the third sound is a long beeping sound without an interval.

[0011] Furthermore, in the above-mentioned safety protection method for counterbalance forklifts, the markers include a first marker and a second marker, wherein the first marker is a pedestrian and the second marker is a vehicle.

[0012] Furthermore, in the above-mentioned safety protection method for counterbalanced forklifts, the preset safety distance is 20~30cm.

[0013] Furthermore, in the above-mentioned safety protection method for counterbalance forklifts, the preset safe speed is 3-5 km / h.

[0014] The safety protection system and method for counterbalanced forklifts of the present invention have the following advantages and positive effects: (1) This invention uses dual cameras set at the front and rear ends of the top guard to cover the front and rear working areas of the forklift respectively, so as to achieve the collection of images without blind spots in the direction of forklift travel, thereby making up for the driver's visual defects from the source. Furthermore, through the three-level protection zones set in stages, it matches the tiered protection logic of graded warning, active speed limit, and forced stop. Low-risk areas only provide prompts and do not interfere with the operation, medium-risk areas provide speed limit warnings and retain operating permissions, and high-risk areas force stop to prevent accidents. This not only achieves full-scene safety protection, but also avoids the operation interruption caused by excessive protection, perfectly adapting to the complex working conditions of forklifts. (2) In the reversing mode, the present invention uses dual detection by the rear camera and radar to make up for the shortcomings of the single vision solution in being unable to identify non-human static obstacles, and also solves the problem of false alarms of the single radar solution in a narrow space. It can achieve accurate detection of all types of obstacles such as pedestrians, vehicles, cargo stacks, walls, ground stakes, and shelves, with no gaps in protection coverage. Furthermore, through the linkage between the display control unit and the throttle speed limit unit, it can achieve active control of the entire process from early warning prompts to active speed limit and then to forced stopping, without relying on the driver's operation response. It completely avoids the safety risks caused by human factors such as driver negligence, misoperation, and accidental acceleration, and meets the high-level safety protection requirements of forklifts. Attached Figure Description

[0015] 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 for further understanding of the embodiments of the present invention and constitute a part of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings: Figure 1 This is a schematic diagram of the safety protection system for the counterbalanced forklift of the present invention; Figure 2 This is a schematic diagram showing the location of the camera area in the safety protection system of the counterbalanced forklift of the present invention.

[0016] Explanation of reference numerals in the attached figures: 11. Overhead support frame; 12. Floor plate; 13. Counterweight; 14. Cab; 2. First camera; 3. Second camera; 4. Display control unit; 5. Radar; 6. Accelerator pedal; A. First area; B. Second area; C. Third area. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0018] This invention provides a safety protection system and method for counterbalanced forklifts, such as... Figure 1 , Figure 2As shown, the forklift has a top guard 11, a bottom plate 12, and a counterweight 13 at the rear. The cab 14 is located between the top guard 11 and the bottom plate 12. The safety system includes a first camera 2 at one end of the top guard 11, a second camera 3 at the other end of the top guard 11, a display control unit 4 in the cab 14 electrically connected to the first and second cameras 2 and 3, a throttle speed limiter (not shown) and a vehicle control unit (not shown) electrically connected within the bottom plate 12, a radar 5 on one side of the counterweight 13 electrically connected to the display control unit 4, and an accelerator pedal 6 at the bottom of the cab 14 connected to the vehicle control unit. The display control unit 4 contains an alarm module (not shown) and is electrically connected to the throttle speed limiter. More specifically, the first camera 2 is fixedly installed at the front end of the top guard 11 (near the forklift mast), specifically at the center of the top of the front crossbeam of the top guard 11; the second camera... The head 3 is fixedly installed at the rear end of the overhead guard 11 (near the counterweight 13), specifically at the center of the top of the rear crossbeam of the overhead guard 11. Together, they form a 360-degree visual coverage of the forklift, enabling blind-spot-free image acquisition and landmark recognition in the forklift's direction of travel. The display control unit 4 is fixedly installed in the dashboard area of ​​the cab 14, specifically at a position directly in front of the driver's line of sight, ensuring the driver can view the entire display without significantly turning their head, thus avoiding distraction. When the forklift is moving forward, the display control unit 4 defaults to displaying the front view of the first camera 2; when the forklift switches to reverse mode, the display control unit 4 automatically switches to displaying the rear view of the second camera 3. The basic function of the accelerator pedal 6 is: the driver outputs a throttle signal corresponding to the pedal travel by pressing the accelerator pedal 6. Under normal, risk-free operating conditions, the throttle signal is transmitted to the vehicle control unit via the throttle speed limiter. The vehicle control unit controls the forklift's drive motor / The engine's output power regulates the forklift's speed; this is the forklift's conventional throttle control logic. The throttle speed limiting unit is the core actuator for active safety control in this system. It has built-in signal conditioning and signal cutoff modules. Its core function is to receive hierarchical control commands output by the display control unit 4 and correspondingly regulate the throttle signal transmitted by the accelerator pedal 6 to achieve active speed limiting and forced stopping. Radar 5 can accurately detect all types of obstacles behind the forklift, including non-human static obstacles (such as stacked goods, walls, ground stakes, shelves, etc.) that are difficult to cover with the visual recognition of the second camera 3. It perfectly makes up for the protection shortcomings of a single visual recognition solution and achieves full coverage detection of all types of obstacles in reversing conditions.

[0019] As a specific implementation, in the safety protection system of the counterbalance forklift of the present invention, the alarm module is a buzzer. Its core function is to receive the graded warning signals output by the display control unit 4, issue sound warnings in different modes, and transmit danger level information to the driver through the auditory channel, so that the driver can quickly judge the surrounding risks by sound alone without looking at the screen, thereby improving the convenience of operation and the speed of emergency response.

[0020] On the other hand, the safety protection method for the counterbalance forklift of the present invention is implemented using the above-mentioned safety protection system, and specifically includes the following steps: Step 1: When the forklift is working, the first camera 2 and the second camera 3 identify the markers in front of and behind the forklift respectively. The camera areas of the first camera 2 and the second camera 3 each include three areas set in a tiered manner: the first area A, which is far away from the forklift; the second area B; and the third area C, which is close to the forklift. Step 2: When the marker enters the first area A, the first camera 2 and the second camera 3 send the corresponding data to the display control unit 4. The display control unit 4 displays the images captured by the first camera 2 and the second camera 3, and the alarm module issues the first sound warning. At the same time, the right side of the display screen of the display control unit 4 displays the warning sign corresponding to the marker, and the forklift continues to work normally. Step 3: When the marker enters the second area B, the first camera 2 and the second camera 3 send the corresponding data to the display control unit 4. The display control unit 4 displays the images captured by the first camera 2 and the second camera 3, and the alarm module emits a second sound warning. At the same time, the right side of the display screen of the display control unit 4 displays the warning sign corresponding to the marker. Simultaneously, the display control unit 4 outputs a signal to the throttle speed limiting unit, and the throttle speed limiting unit reduces the throttle signal transmitted from the accelerator pedal 6 to the vehicle control unit. The forklift travels at the preset safe speed. Step 4: When the marker enters the third area C, the first camera 2 and the second camera 3 send the corresponding data to the display control unit 4. The display control unit 4 displays the images captured by the first camera 2 and the second camera 3, and the alarm module emits a third sound warning. At the same time, the right side of the display screen of the display control unit 4 displays the warning sign corresponding to the marker. Simultaneously, the display control unit 4 outputs a signal to the throttle speed limiting unit, which cuts off the throttle signal transmitted from the accelerator pedal 6 to the vehicle control unit, and the forklift decelerates until it comes to a complete stop.

[0021] In one specific implementation, in the safety protection method of the counterbalance forklift of the present invention, when the forklift is reversing, the display control unit 4 displays the image captured by the second camera 3, and the radar 5 is activated to detect obstacles behind the counterweight 13. When the radar 5 detects that the distance between the obstacle and the forklift is greater than a preset safe distance, it transmits a signal to the display control unit 4, and the alarm module issues a second sound warning. Simultaneously, the display control unit 4 outputs a signal to the throttle speed limiting unit, and the throttle speed limiting unit reduces the throttle signal transmitted from the accelerator pedal 6 to the vehicle control unit. The forklift travels at a preset safe speed. When the distance between the obstacle and the forklift is detected to be less than the preset safe distance, the alarm module issues a third sound warning, and the display control unit 4 outputs a signal to the throttle speed limiting unit, and the throttle speed limiting unit cuts off the throttle signal transmitted from the accelerator pedal 6 to the vehicle control unit. The forklift decelerates until it comes to a complete stop.

[0022] As one specific implementation method, in the safety protection method for counterbalanced forklifts of the present invention, the first area A is a passage area displayed in green, the second area B is a warning area displayed in yellow, and the third area C is a warning area displayed in red. The boundary distance between the three areas can be preset and adjusted according to the forklift's operating scenario, rated load, and normal driving speed to adapt to the protection requirements of different working conditions.

[0023] In one specific implementation, in the safety protection method of the counterbalance forklift of the present invention, the first sound is a buzzer with an interval of 1-1.5 seconds, which only serves as a reminder and does not interfere with the driver's normal operation; the second sound is a buzzer with an interval of 0.3-0.7 seconds, which serves as a strong warning and reminds the driver to slow down immediately and pay attention to avoid the obstacle; the third sound is a long beep with no buzzer interval, which serves as an emergency warning and forcibly reminds the driver that the obstacle has entered the danger distance, and, in conjunction with the forced stop action, avoids the risk of collision.

[0024] In one specific implementation, the safety protection method for the counterbalance forklift of the present invention includes a first marker and a second marker, wherein the first marker is a pedestrian and the second marker is a vehicle.

[0025] As one specific implementation method, in the safety protection method for counterbalanced forklifts of the present invention, the preset safety distance is 20~30cm, and more specifically, the preset safety distance is set to 25cm.

[0026] In one specific implementation, the safety protection method for the counterbalance forklift of the present invention has a preset safe speed of 3-5 km / h, and more specifically, the preset safe speed is set to 4 km / h.

[0027] In summary, compared with the prior art, the safety protection system and method for counterbalanced forklifts of the present invention have the following advantages and positive effects: (1) The present invention uses dual cameras set at the front and rear ends of the top guard 11 to cover the front and rear working areas of the forklift respectively, so as to achieve the collection of images without blind spots in the direction of forklift travel, thereby making up for the driver's visual defects from the source. Furthermore, through the three-level protection zones set in stages, the invention matches the tiered protection logic of graded warning, active speed limit, and forced stop. In low-risk areas, only prompts are given without interfering with the operation; in medium-risk areas, speed limit warnings are given and operation permissions are retained; and in high-risk areas, forced stop is implemented to prevent accidents. This not only achieves full-scene safety protection but also avoids the interruption of operation caused by excessive protection, perfectly adapting to the complex working conditions of forklifts. (2) In the reversing mode, the present invention uses the dual detection of the rear camera and radar 5 to make up for the shortcomings of the single vision solution in being unable to identify non-human static obstacles, and also solves the problem of false alarms in a narrow space by the single radar 5 solution. It can achieve accurate detection of all types of obstacles such as pedestrians, vehicles, cargo stacks, walls, ground stakes, and shelves, with no gaps in protection coverage. Furthermore, through the linkage between the display control unit 4 and the throttle speed limit unit, it can achieve active control of the entire process from early warning prompts to active speed limit and then to forced stopping. It does not need to rely on the driver's operation response, and completely avoids the safety risks caused by human factors such as driver negligence, misoperation, and accidental acceleration, thus meeting the high-level safety protection requirements of forklifts.

[0028] It should be noted that, unless otherwise expressly specified and limited, the term "connection" or its synonyms should be interpreted broadly in this document. For example, "connection" can be a fixed connection or a detachable 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 communication of two elements or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Furthermore, expressions such as "first" and "second" are merely used to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Meanwhile, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In addition, the terms "front," "rear," "left," "right," "upper," and "lower" in this document refer to the placement states shown in the accompanying drawings.

[0029] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A safety protection system for a counterbalance forklift, wherein the forklift has a top guard, a bottom plate, and a counterweight at the rear, and the cab is located between the top guard and the bottom plate, characterized in that... The safety protection system includes a first camera located at one end of the roof guard, a second camera located at the other end of the roof guard, a display control unit located in the cab and electrically connected to the first camera and the second camera, a throttle speed limiter unit and a vehicle control unit located in the floor and electrically connected to each other, a radar located on one side of the counterweight and electrically connected to the display control unit, and an accelerator pedal located at the bottom of the cab and connected to the vehicle control unit. The display control unit is equipped with an alarm module and is electrically connected to the throttle speed limiter unit.

2. The safety protection system for a counterbalance forklift according to claim 1, characterized in that, The alarm module is a buzzer.

3. A safety protection method for a counterbalance forklift, said safety protection method being implemented using the safety protection system as described in any one of claims 1 to 2, comprising: Step 1: When the forklift is working, the first camera and the second camera respectively identify the markers in front of and behind the forklift. The camera areas of the first camera and the second camera each include three areas set in a tiered manner: a first area away from the forklift, a second area, and a third area close to the forklift. Step 2: When the marker enters the first area, the first camera and the second camera send corresponding data to the display control unit. The display control unit displays the images captured by the first camera and the second camera, and the alarm module issues a first sound warning. At the same time, the right side of the display screen of the display control unit displays the warning sign corresponding to the marker, and the forklift continues to operate normally. Step 3: When the marker enters the second area, the first camera and the second camera send corresponding data to the display control unit. The display control unit displays the images captured by the first camera and the second camera, and the alarm module issues a second audible warning. At the same time, the right side of the display screen of the display control unit displays the warning sign corresponding to the marker. Simultaneously, the display control unit outputs a signal to the throttle speed limiting unit, and the throttle speed limiting unit reduces the throttle signal transmitted from the accelerator pedal to the vehicle control unit, so that the forklift travels at a preset safe speed. Step 4: When the marker enters the third area, the first camera and the second camera send corresponding data to the display control unit. The display control unit displays the images captured by the first camera and the second camera, and the alarm module issues a third sound warning. At the same time, the right side of the display screen of the display control unit displays the warning sign corresponding to the marker. Simultaneously, the display control unit outputs a signal to the throttle speed limiting unit, and the throttle speed limiting unit cuts off the throttle signal transmitted from the accelerator pedal to the vehicle control unit. The forklift decelerates until it comes to a complete stop.

4. The safety protection method for a counterbalance forklift according to claim 3, characterized in that, When the forklift is reversing, the display control unit displays the image captured by the second camera. Simultaneously, the radar is activated to detect obstacles behind the counterweight. When the radar detects an obstacle beyond a preset safe distance from the forklift, it transmits a signal to the display control unit, and the alarm module issues a second audible warning. Simultaneously, the display control unit outputs a signal to the throttle speed limiting unit, which reduces the throttle signal transmitted from the accelerator pedal to the vehicle control unit. The forklift travels at a preset safe speed. When an obstacle is detected beyond the preset safe distance, the alarm module issues a third audible warning, and the display control unit outputs a signal to the throttle speed limiting unit, which cuts off the throttle signal transmitted from the accelerator pedal to the vehicle control unit. The forklift decelerates until it comes to a complete stop.

5. The safety protection method for a counterbalance forklift according to claim 3, characterized in that, The first area is a green passage area, the second area is a yellow warning area, and the third area is a red alert area.

6. The safety protection method for a counterbalance forklift according to claim 3, characterized in that, The first sound is a beeping sound with an interval of 1-1.5 seconds, the second sound is a beeping sound with an interval of 0.3-0.7 seconds, and the third sound is a long beeping sound without an interval.

7. The safety protection method for a counterbalance forklift according to claim 3, characterized in that, The signage includes a first signage and a second signage, wherein the first signage is a pedestrian and the second signage is a vehicle.

8. The safety protection method for a counterbalance forklift according to claim 3, characterized in that, The preset safety distance is 20~30cm.

9. The safety protection method for a counterbalance forklift according to claim 3, characterized in that, The preset safe speed is 3-5 km / h.

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