An OPS safety control system for electric forklifts

Abstract

The utility model discloses an OPS safety control system for an electric forklift, belonging to the technical field of forklift safety. The system includes a seat pressure sensing module, a driver authentication module, a seat belt detection module, a positioning module, a controller, and a forklift motion control device, wherein the signal output ends of the seat pressure sensing module, the driver authentication module, the seat belt detection module, and the positioning module are respectively connected to the signal input ends of the controller, and the output end of the controller is connected to the corresponding forklift motion control device. The utility model realizes that only when the driver authenticated by the forklift sits in the seat and fastens the seat belt and passes the face recognition in the safe area, the forklift can be operated, thereby ensuring the safe operation of the forklift.

Description

Technical Field

[0001] The utility model belongs to the technical field of forklift safety, and specifically relates to an OPS safety control system of an electric forklift. Background Art

[0002] Forklifts, as a type of handling equipment widely used in logistics, warehousing, manufacturing and other fields, their safety issues cannot be ignored. The existing OPS safety protection system (OPS stands for Operator Presence Sensing, which refers to a safety system that uses a seat sensor installed on the driver's seat to sense whether the driver is sitting in the driver's seat in the correct posture). The existing OPS system only uses seat sensors for detection. For the complex working conditions of forklifts, it cannot accurately determine whether the driver certified by the forklift is in the seat.

[0003] In accordance with the requirements of TSG81-2022 "Technical Safety Regulations for Special Motor Vehicles within the Yard (Factory)", the main function of the OPS safety protection system is that rider-type electric forklifts, rider-type internal combustion counterbalanced forklifts with electro-hydraulic reversing, and rider-type internal combustion side-mounted forklifts with electro-hydraulic reversing should be equipped with a driver's sitting (standing) posture perception system. When the driver is not in the normal operating position, the vehicle cannot be powered. Even if the load loading and unloading control device is operated, the mast should not tilt or the fork frame should not move; when the driver returns to the normal operating position but does not perform additional operations, power operation, mast tilting, and fork frame movement should not occur automatically.

[0004] The comparative document (CN201621050123.7) discloses a forklift OPS control system. This patent realizes the control of the lifting and lowering of the forklift by setting a seat gravity sensor. When the forklift driver is not sitting on the forklift seat, the seat gravity sensor cannot detect gravity and transmits the signal to the central controller. At this time, the central controller prohibits the solenoid valve group from operating, and the forklift cannot perform lifting and lowering actions. When the forklift driver leaves the forklift seat during operation, the seat gravity sensor cannot detect gravity and transmits the signal to the central controller. The central controller controls the solenoid valve group to operate, and the lifting or lowering action of the forklift stops; when the forklift is reversing, the central controller controls the buzzer and warning light to turn on to alert pedestrians.

[0005] However, the above-mentioned reference document does not give any reminders for not fastening the seat belt, but only detects whether the driver is sitting on the seat, and uses a seat gravity sensor to simply detect gravity. When using a mass block or other objects similar to human weight, it is easy to bypass the detection means, and the risk of operating the vehicle still exists; and it cannot be guaranteed that the driver certified by the forklift controls the forklift; at the same time, the structure of the reference document is redundant, and does not consider the situation of a two-in-one traction and lifting controller and multiple controllers. For this reason, the utility model proposes an OPS safety control system for an electric forklift. Utility Model Content

[0006] The utility model aims to overcome the deficiencies of the prior art and proposes an OPS safety control system for an electric forklift, so that the forklift can only be operated in a safe area when a driver certified by the forklift sits in a seat, wears a seat belt and passes face recognition, thereby ensuring the safe operation of the forklift.

[0007] In order to achieve the above-mentioned purpose, the technical solution adopted by the utility model is: an OPS safety control system of an electric forklift, including a seat pressure sensing module, a driver authentication module, a seat belt detection module, a positioning module, a controller, and a forklift motion control device, wherein the signal output ends of the seat pressure sensing module, the driver authentication module, the seat belt detection module, and the positioning module are respectively connected to the signal input ends of the controller, and the output end of the controller is connected to the corresponding forklift motion control device.

[0008] Furthermore, the driver authentication module includes a power module, an authentication device, and a relay, wherein the power module is connected to the forklift power supply; the authentication device is connected to the control end of the relay; and the relay is connected to the controller to send the corresponding switch signal to the controller.

[0009] Furthermore, the relay is a normally open relay. When the authentication device detects that the driver on the forklift seat is authenticated by the forklift, the normally open relay is closed; when the authentication device does not detect that the driver on the forklift seat is authenticated by the forklift, the normally open relay remains in an open state.

[0010] Furthermore, the authentication device is a face recognition camera.

[0011] Furthermore, the seat belt detection module includes a buckle plug feedback device and a relay, wherein the buckle plug feedback device is connected to the control end of the relay; the relay is connected to the controller and is used to send the corresponding switch signal to the controller.

[0012] Furthermore, the seat pressure sensing module includes a pressure sensor, a timer, and a relay, wherein the pressure sensor and the timer are respectively connected to the control end of the relay; the relay is connected to the controller for sending the corresponding switch signal to the controller; and the timer is connected to the pressure sensor.

[0013] Furthermore, the positioning module includes a locator and an electronic fence, which are respectively connected to the controller; the electronic fence is used to define in advance an area where the forklift can work safely, and the locator is used to detect the position of the forklift in real time and determine whether it exceeds the area defined by the electronic fence.

[0014] Furthermore, the positioner is connected to the controller via a CAN bus or an RS485 bus.

[0015] Furthermore, when there is only one controller, the controller receives and processes signals and outputs control signals to the corresponding forklift motion control device; when there are more than one controller, one of the controllers is selected as the main controller, and all the remaining controllers are slave controllers, and the slave controllers are connected to the main controller respectively, wherein the main controller is used to receive and process signals and assign tasks to each slave controller, and the slave controllers are used to output control signals to the corresponding forklift motion control device according to the tasks assigned by the main controller.

[0016] Furthermore, the forklift motion control device includes a solenoid valve for controlling the lifting motion of the cargo fork and a motor for controlling the traveling motion of the forklift.

[0017] The technical effects of the utility model are as follows: (1) a face recognition camera is provided to ensure that the driver is certified by the forklift to drive, thereby avoiding the situation where the seat posture perception is deceived by stacking heavy objects; (2) a timer is added on the basis of the original seat pressure sensor to avoid the misjudgment caused by the driver leaving the seat for a short time when the forklift working condition is relatively bad, thereby ensuring the safety of the forklift; (3) a seat belt detection module is provided to ensure that the driver wears the seat belt safely to ensure safety; (4) a positioning module is provided to ensure that the forklift is driving in a safe area with the help of an electronic fence and a locator; (5) taking into account the situation of multiple controllers, by setting up a master-slave controller, wiring harnesses are saved and the failure rate caused by the connection of multiple wiring harnesses is reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a system structure diagram of an embodiment of the utility model;

[0019] Figure 2 Schematic diagram of the structure of the driver authentication module of the embodiment of the utility model. DETAILED DESCRIPTION

[0020] The following is a further detailed description of the specific implementation of the utility model through the description of the embodiments with reference to the accompanying drawings, with the purpose of helping those skilled in the art to have a more complete, accurate and in-depth understanding of the utility model concept and technical solution of the utility model and to facilitate its implementation. In the utility model, the "connection" includes both signal transmission and data interaction achieved by wired connection with actual lines, and signal transmission and data interaction achieved by wireless connection achieved by wireless transmission technology.

[0021] In order to make the technical solution of the utility model clearer, the utility model is explained through the following embodiments:

[0022] Embodiment 1:

[0023] An OPS safety control system for an electric forklift, such as Figure 1 As shown, it includes a seat pressure sensing module, a driver authentication module, a seat belt detection module, a positioning module, a controller, and a forklift motion control device, wherein the signal output ends of the seat pressure sensing module, the driver authentication module, the seat belt detection module, and the positioning module are respectively connected to the signal input ends of the controller through a CAN bus, and the output end of the controller is connected to the corresponding forklift motion control device through a CAN bus. The forklift motion control device includes a solenoid valve for controlling the lifting movement of the cargo fork and a motor for controlling the travel movement of the forklift, and the controller is a controller chip commonly used in forklifts, such as an MCU and an ECU. In this embodiment, only a single controller is used for two-in-one control of traction and lifting, that is, the controller controls the traction and lifting actions of the vehicle according to the signals of each system and each module.

[0024] Specifically, the driver authentication module includes a power module, an authentication device, and a relay, wherein the power module is connected to the forklift power supply; the authentication device is connected to the control end of the relay; and the relay is connected to the controller to send the corresponding switch signal to the controller. Figure 2 The authentication device is a face recognition camera, the power module is a power coil, the relay is a normally open relay, and the B- and B+ pins of the power coil are respectively connected to the negative and positive poles of the forklift power supply.

[0025] When the forklift starts the forklift power supply through the key switch, the power coil is energized, and the face recognition camera starts to work, and the driver on the seat is recognized by the face recognition camera. When the face recognition camera detects the driver on the forklift seat who is authenticated by the forklift, the normally open relay is closed; when the face recognition camera does not detect the driver on the forklift seat who is authenticated by the forklift, the normally open relay remains in the open state, and continues to try to identify twice until the authentication is passed. The driver authentication module enters the sleep mode and continues to work when the forklift is powered on again. The face recognition verification method ensures that only the driver authenticated by the forklift can operate the forklift, avoiding the situation of deceiving the seat posture perception by stacking heavy objects. The driver authentication module is set in the forklift, and the personnel perform information maintenance, including but not limited to adding or deleting the face information of the driver authenticated by the forklift. Further, in the specific implementation, the authentication device can also be a pupil recognition, fingerprint verification and other devices, and it only needs to ensure that the forklift can only be operated by the set driver.

[0026] Specifically, the seat belt detection module includes a buckle plug feedback device and a normally closed relay, wherein the buckle plug feedback device is connected to the control end of the normally closed relay; the normally closed relay is connected to the controller to send the corresponding switch signal to the controller; when the buckle plug feedback device detects that the driver has fastened the seat belt, that is, when the buckle contacts the seat belt spring tongue, the normally closed relay opens; when the buckle plug feedback device does not detect that the driver has fastened the seat belt, the normally closed relay remains in a closed state. The setting of the seat belt detection module ensures that the forklift driver can only operate the forklift after fastening the seat belt, ensuring the driver's safety. In specific implementation, the seat belt detection module can also use components such as a seat belt position detection device, as long as it can detect whether the seat belt is worn correctly.

[0027] Specifically, the seat pressure sensing module includes a pressure sensor, a timer, and a normally open relay. The pressure sensor and the timer are respectively connected to the control end of the normally open relay; the normally open relay is connected to the controller to send the corresponding switch signal to the controller; the timer is connected to the pressure sensor.

[0028] In this embodiment, a first timer is set to record the time during which the pressure detected by the pressure sensor is greater than or equal to a preset pressure threshold. When the timing time is less than the preset holding time threshold, it is regarded as the driver is not in the seat and the normally open relay remains open; when the timing time is greater than or equal to the preset holding time threshold, it is regarded as the driver is in the seat and the normally open relay is closed.

[0029] A second timer is set to record the time of leaving when the pressure detected by the pressure sensor is less than the preset pressure threshold. When the timing time is less than the preset threshold of leaving time, it is considered that the driver is in the seat, and the normally open relay is closed; when the timing time is greater than or equal to the preset threshold of leaving time, it is considered that the driver has left the seat, and the normally open relay is opened. Considering that the operating conditions of the forklift are relatively poor, when the forklift is driving on bumpy roads, the driver may be shaken and leave the seat for a short time. Adding a timer can avoid the forklift from starting by mistake due to misjudgment, thereby ensuring safety. In this embodiment, the threshold of leaving time is set to 3 seconds, and if the gravity sensor is not detected within 3 seconds, it is considered that the driver has left the seat.

[0030] The positioning module is an important component of the forklift intelligent management system, and it mainly undertakes the two core functions of longitude and latitude information positioning and parking electronic fence implementation. The realization of these functions not only enhances the positioning accuracy and safety of the forklift, but also improves the efficiency of logistics operations. Specifically, the positioning module includes a locator and an electronic fence, and the locator and the electronic fence are respectively connected to the controller; the electronic fence is used to demarcate the safe working area of ​​the forklift in advance, and the locator is used to detect the position of the forklift in real time and determine whether it exceeds the area demarcated by the electronic fence. In specific implementation, the locator can select GPS or Beidou satellite navigation system to locate the longitude and latitude information of the forklift.

[0031] When the forklift is in the safe area defined by the electronic fence, the positioning module will send a normal working signal to the controller. In order to ensure the reliability and stability of communication, the locator and the controller are connected via the CAN bus first. When the CAN bus is unavailable, the RS485 bus is used as a secondary choice. After receiving the normal working signal, the controller controls the forklift normally to ensure that the forklift operates within the permitted range.

[0032] When the forklift is outside the electronic fence, the system will perform face recognition to ensure that the driver's identity is legal. At the same time, the system will detect whether the driver is in the seat and whether the seat belt is fastened. When any of the conditions of driver identity recognition failure, driver not in the seat, and seat belt not being fastened exists, the positioning module will send an abnormal signal to the controller. After receiving the abnormal signal, the controller will reduce the vehicle performance to 80% of the rated performance to reduce the potential risk of the forklift in an illegal area. At the same time, in this embodiment, a voice alarm device can be added, which is connected to the output end of the controller. When the forklift is outside the electronic fence, the controller can remind the driver through the voice alarm device and require it to work within the authorized geographical range. When there is any situation of face recognition failure, driver not in the seat or seat belt not being fastened, the priority of the interaction between the remaining modules and the controller will be higher than the positioning module. The setting of the positioning module improves the positioning accuracy and safety of the forklift, while ensuring that the forklift works in a safe area. When it exceeds the range, the driver's safety will be given priority.

[0033] The forklift motion control device and the controller have a logic of mutual interactive feedback and are in a closed-loop system. On the one hand, the controller comprehensively gives control logic to the corresponding forklift motion control device based on the signals of each module in the system to decide whether the forklift is allowed to take corresponding actions; on the other hand, the forklift motion control device also feeds back the status of the corresponding solenoid valves of the forklift driving and fork action it controls to the controller, which facilitates system control and improves work efficiency.

[0034] In summary, the system of the utility model realizes that the forklift can only be operated in a safe area when the driver certified by the forklift sits in the seat, wears the seat belt and passes the face recognition. When any of the above conditions is not met, the forklift will not start, thereby ensuring the safe operation of the forklift.

[0035] Embodiment 2:

[0036] Different from the single controller adopted in the first embodiment, the second embodiment adopts at least two controllers on the basis of the single controller. At this time, one of the controllers is selected as the main controller, and all the remaining controllers are slave controllers. The signal output ends of the seat pressure sensing module, the driver authentication module, the seat belt detection module, and the positioning module are respectively connected to the signal receiving end of the main controller through the CAN bus, and all the remaining slave controllers are respectively connected to the main controller, wherein the main controller is used to receive and process signals and assign tasks to each slave controller, and the slave controller is used to output control signals to the corresponding forklift motion control device according to the tasks assigned by the main controller. In the CAN bus, the main controller is regarded as the master node, and the slave controller is regarded as the slave node. The input signal is connected to the master node controller, and the master node controller controls other slave node controllers to complete the lifting and traction action logic control of the electric forklift; the wiring harness is saved, the wiring harness cost is reduced, and the failure rate caused by the connection of multiple wiring harnesses is reduced.

[0037] The above is an exemplary description of the utility model in conjunction with the accompanying drawings. Obviously, the specific implementation of the utility model is not limited to the above-mentioned method. As long as various non-substantial improvements are made using the method concept and technical solution of the utility model; or the above concept and technical solution of the utility model are directly applied to other occasions without improvement, they are all within the protection scope of the utility model.

Claims

1. An OPS safety control system for an electric forklift, comprising a seat pressure sensing module, characterized in that: It also includes a driver authentication module, a seat belt detection module, a positioning module, a controller, and a forklift motion control device, wherein the signal output ends of the seat pressure sensing module, the driver authentication module, the seat belt detection module, and the positioning module are respectively connected to the signal input end of the controller, and the output end of the controller is connected to the corresponding forklift motion control device.

2. The OPS safety control system of an electric forklift according to claim 1, characterized in that: The driver authentication module includes a power module, an authentication device, and a relay, wherein the power module is connected to the forklift power supply; the authentication device is connected to the control end of the relay; and the relay is connected to the controller to send the corresponding switch signal to the controller.

3. The OPS safety control system of an electric forklift according to claim 2, characterized in that: The relay is a normally open relay. When the authentication device detects that the driver on the forklift seat is authenticated by the forklift, the normally open relay is closed; when the authentication device does not detect that the driver on the forklift seat is authenticated by the forklift, the normally open relay remains open.

4. The OPS safety control system of an electric forklift according to claim 2 or 3, characterized in that: The authentication device is a face recognition camera.

5. The OPS safety control system of an electric forklift according to claim 1, characterized in that: The seat belt detection module includes a buckle plug feedback device and a relay, wherein the buckle plug feedback device is connected to the control end of the relay; the relay is connected to the controller and is used to send the corresponding switch signal to the controller.

6. The OPS safety control system of an electric forklift according to claim 1, characterized in that: The seat pressure sensing module includes a pressure sensor, a timer, and a relay. The pressure sensor and the timer are respectively connected to the control end of the relay; the relay is connected to the controller to send the corresponding switch signal to the controller; the timer is connected to the pressure sensor.

7. The OPS safety control system of an electric forklift according to claim 1, characterized in that: The positioning module includes a locator and an electronic fence, which are respectively connected to the controller; the electronic fence is used to define in advance an area where the forklift can work safely, and the locator is used to detect the position of the forklift in real time and determine whether it exceeds the area defined by the electronic fence.

8. The OPS safety control system of an electric forklift according to claim 7, characterized in that: The positioner is connected to the controller via a CAN bus or an RS485 bus.

9. The OPS safety control system of an electric forklift according to claim 1, characterized in that: When there is only one controller, the controller receives and processes signals and outputs control signals to the corresponding forklift motion control device; when there are more than one controller, one of the controllers is selected as the main controller, and all the remaining controllers are slave controllers, and the slave controllers are connected to the main controller respectively, wherein the main controller is used to receive and process signals and assign tasks to each slave controller, and the slave controller is used to output control signals to the corresponding forklift motion control device according to the tasks assigned by the main controller.

10. The OPS safety control system of an electric forklift according to claim 1, characterized in that: The forklift motion control device comprises a solenoid valve for controlling the lifting motion of the cargo fork and a motor for controlling the traveling motion of the forklift.

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