Safety early warning system of electric forklift

Abstract

The utility model discloses a safety early warning system of an electric forklift, and belongs to the technical field of forklift safety. The device comprises a detection device, a signal relay device, a display device and an acousto-optic prompt device, and the output end of the detection device is connected with the input end of the signal relay device; the output end of the signal relay device is connected with the input end of the display device, and the output end of the display device is connected with the input end of the acousto-optic prompt device. According to the utility model, timely and accurate safety early warning is provided for a forklift driver through a man-machine interaction system, the personnel safety is ensured, the intelligent and digital level of the forklift is improved, and the operation experience of the driver is improved.

Description

Technical Field

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

[0002] Forklifts play an important role in logistics and industry. They can move goods quickly and efficiently, improving production efficiency. Traditional forklift warning systems mainly use simple lamps for regional prompts (such as blue light strips forming a "mouth"-shaped light strip); or use speakers, buzzers and other sounds for warnings. This warning method has some problems. For example, it is not easy for operators to distinguish which signal is from another forklift from different sounds and lights, and it is difficult to hear the alarm sound in places with high environmental noise.

[0003] In addition, the traditional early warning system cannot monitor the objects around the forklift in real time, lacking accuracy and timeliness. In this context, intelligent forklift safety zone management technology has been rapidly introduced, which is roughly divided into acquisition module, control system, alarm system, and data processing system; compared with the traditional early warning system, its advantages are: 1. Improve safety: The forklift safety zone system monitors and perceives the surrounding environment by installing sensors, cameras and other acquisition module equipment to avoid collisions and dangerous situations, thereby improving the safety of forklift operation. 2. Improve efficiency: The forklift safety zone system can reduce the occurrence of forklift accidents, reduce the cost of repairs and maintenance, and at the same time improve work efficiency and reduce production costs. 3. Digitalization: The forklift safety zone system can record and analyze the safety alarm data of the forklift, providing data support for decision makers to analyze the causes of unsafe behaviors and corresponding rectification.

[0004] The comparative document (CN116902878A) discloses a forklift anti-collision system and a control method thereof. After obtaining the high-impact signal generated during ultrasonic radar obstacle detection, the comparative document generates a number of impact indexes subsequently generated during ultrasonic radar obstacle detection to establish a data set, analyzes the impact indexes in the data set, analyzes the impact situation during ultrasonic radar obstacle detection, and issues an early warning prompt or no early warning for the analyzed result. However, the comparative document adopts a formula for numerical calculation by removing dimensions. The formula is a formula for the most recent real situation obtained by software simulation of a large amount of data collected. The preset parameters in the formula are set by technicians in this field according to the actual situation. There are many models of forklift manufacturers and ultrasonic probes, and the installation method, position, and angle of the camera will affect the accuracy. The real situation is extremely complicated to define the collected data. At the same time, the comparative document does not have safety detection of people around the forklift, and safety detection of driver behavior, which has potential safety hazards. To this end, the utility model proposes a safety early warning system for electric forklifts. Utility Model Content

[0005] The utility model aims to overcome the deficiencies of the prior art and proposes a safety warning system for an electric forklift, so as to provide timely and accurate safety warnings to forklift drivers through a human-computer interaction system, ensure personnel safety, improve the intelligence and digitization level of forklifts, and improve the driver's operating experience.

[0006] In order to achieve the above-mentioned purpose, the technical solution adopted by the utility model is: a safety warning system for an electric forklift, the system comprising a detection device, a signal relay device, a display device, and a sound and light prompt device, wherein the output end of the detection device is connected to the input end of the signal relay device; the output end of the signal relay device is connected to the input end of the display device, and the output end of the display device is connected to the input end of the sound and light prompt device.

[0007] Furthermore, the output end of the detection device is connected to the input end of the sound and light prompting device.

[0008] Furthermore, the detection device includes an infrared sensor, an ultrasonic sensor, and a DSM driver behavior camera, and the output ends of the infrared sensor, ultrasonic sensor, and DSM driver behavior camera are respectively connected to the input end of the signal relay device, wherein the infrared sensor is used to output an alarm signal when a person is detected within a dangerous range; the ultrasonic sensor is used to output a detection signal of the real-time position of the forklift, and output an alarm signal when an obstacle is detected within the dangerous range; the DSM driver behavior camera is used to output an alarm signal when abnormal driving behavior of the driver is detected, and the abnormal driving behavior includes the driver dozing off or making a phone call. Furthermore, when the infrared sensor and the ultrasonic sensor output alarm signals at the same time, the alarm signal of the infrared sensor is output first.

[0009] Furthermore, the output ends of the infrared sensor, ultrasonic sensor, and DSM driver behavior camera and the input end of the signal relay device, as well as the output end of the signal relay device and the input end of the display device are all connected via a CAN bus. Furthermore, the CAN bus data transmission rate between the infrared sensor, ultrasonic sensor, DSM driver behavior camera and the signal relay device is 125Kbps.

[0010] Furthermore, the display device is an IoT screen, and the input end of the IoT screen is connected to the output end of the signal relay device. The IoT screen includes a memory, a controller, and a communication module. The memory is used to record alarm information, and the alarm information includes the time, category, and sequence number of the alarm event. The controller is used to send a control signal according to the output of the signal relay device to control the IoT screen to display pictures and texts and the sound and light prompt device to perform sound and light prompts. The communication module includes GPS and 4GLTE signal communication devices, which are used to communicate with the server.

[0011] Furthermore, the detection device is used to detect the state of the forklift and the driver's behavior, and output an alarm signal when a dangerous situation occurs, wherein the dangerous situation includes the presence of a person or obstacle within the safety range of the forklift and abnormal driver behavior; the signal relay device is used to convert the alarm signal output by the detection device and assemble it into a corresponding message and then output it to the display device; the display device is used to verify and process the message output by the signal relay device, and then send a control signal to control the display device to display graphics and text, and control the sound and light prompt device to perform sound and light prompts; when the display device fails, the sound and light prompt device is used to directly perform sound and light prompts according to the alarm signal output by the display device.

[0012] The technical effects of the utility model are as follows: (1) multiple sensors are used to realize comprehensive detection of people, obstacles and driver behaviors, with diverse detection, clearly defining the scope of the safety zone and reducing false alarms; (2) based on the human-computer interaction method, when the forklift driver is at risk of overturning due to line of sight obstruction, cargo obstruction, etc., the forklift can be safely operated according to the display device and the sound and light prompt device to ensure safety and improve work efficiency; (3) when people and obstacles appear within the working range of the forklift at the same time, the safety of people is prioritized to reduce the occurrence of safety accidents. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a system structure diagram of Embodiment 1 of the present utility model;

[0014] Figure 2 This is a system structure diagram of Embodiment 2 of the present utility model;

[0015] Figure 3 This is a schematic diagram of components of a detection device according to Embodiment 2 of the present utility model;

[0016] Figure 4 This is a schematic diagram of the IoT screen page display of the second embodiment of the present utility model. DETAILED DESCRIPTION

[0017] 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.

[0018] In order to make the technical solution of the utility model clearer, the utility model is explained through the following embodiments:

[0019] Embodiment 1:

[0020] like Figure 1 A safety warning system for an electric forklift is shown, the system comprising a detection device, a signal relay device, a display device, and a sound and light prompt device, wherein the output end of the detection device is connected to the input end of the signal relay device; the output end of the signal relay device is connected to the input end of the display device, and the output end of the display device is connected to the input end of the sound and light prompt device.

[0021] Furthermore, the output end of the detection device is also connected to the input end of the sound and light prompt device. Thus, the present embodiment realizes two paths of electric forklift warning, namely, prompt path A and prompt path B. When the present embodiment works normally, namely, when the heartbeat message exchange between the display device and all other devices is normal, the safety warning prompt of the electric forklift executes prompt path B, including the graphic display of the display device and the sound and light prompt of the sound and light prompt device; prompt path A means that when the display device is not configured or fails, the sound and light prompt device can directly perform the alarm function prompt separately through the alarm signal of the detection device, which can greatly improve the safety of the forklift during use.

[0022] Specifically, when this embodiment is working, the detection device is used to detect the forklift status and the driver's behavior, and output an alarm signal when a dangerous situation occurs. The dangerous situation includes the presence of a person or obstacle within the safety range of the forklift and abnormal driver behavior; the signal relay device is used to convert the alarm signal output by the detection device and assemble it into a corresponding message and then output it to the display device; the display device is used to verify and process the message output by the signal relay device, and then send a control signal to control the display device to display graphics and text, and control the sound and light prompt device to perform sound and light prompts; when the display device fails, the sound and light prompt device is used to directly perform sound and light prompts according to the alarm signal output by the display device.

[0023] Embodiment 2:

[0024] Based on the solution described in Example 1, the present invention provides Example 2, that is, Figure 2 A safety warning system for an electric forklift is shown, wherein the detection device uses multiple sensors, namely, an infrared sensor, an ultrasonic sensor, and a DSM driver behavior camera; and the display device uses an IoT screen.

[0025] Specifically, the detection device components are as follows Figure 3 As shown, the detection device includes an infrared sensor, an ultrasonic sensor, and a DSM driver behavior camera, and the output ends of the infrared sensor, ultrasonic sensor, and DSM driver behavior camera are respectively connected to the input end of the signal relay device. In specific implementation, the infrared sensor and ultrasonic sensor can be fixed on the overhead guard of the forklift through a mounting bracket, and the DSM driver behavior camera can be installed on the rectangular tube of the forklift. In addition to the above components working independently, the infrared sensor, ultrasonic sensor, and DSM driver behavior camera can also be integrated to work together; the infrared sensor, ultrasonic sensor, and DSM driver behavior camera all use the forklift battery to provide power to the sensor, and the sensor is electrically connected to the main controller, and the main controller is electrically connected to the Internet of Things screen. The main controller is used to control the operation of the sensor and the Internet of Things screen.

[0026] The detection device is mainly responsible for data collection and generation in the system. Specifically, the infrared sensor is used to output an alarm signal when a person is detected within the danger range; the ultrasonic sensor is used to output a detection signal of the real-time position of the forklift, and output an alarm signal when an obstacle is detected within the danger range; the DSM driver behavior camera is used to output an alarm signal when abnormal driving behavior of the driver is detected, and the abnormal driving behavior includes driver dozing off and talking on the phone.

[0027] Infrared sensors can accurately identify the human body and can adapt to various light source environments, that is, they can detect at night, in backlight, etc. At the same time, when the driver wears a hat, glasses, sunglasses, or a mask, the infrared characteristics can penetrate the sunglasses lens, and the blocked eye information can also be imaged normally, which well solves the problem of the driver's glasses reflecting or wearing sunglasses. This embodiment uses multiple sensors to achieve comprehensive detection of people, obstacles, and driver behavior, with diverse detection, clearly defining the safe area and dangerous area, and reducing false alarms.

[0028] Furthermore, in this embodiment, the sensor supports the CAN bus, converts the RS485 bus commonly used in industry into a differential signal of the CAN bus through a conversion card, and then sends the data contained in the differential signal to the CAN bus network at a fixed period through a signal relay device, and the IoT screen receives data from the CAN bus network. Specifically, the output end of the infrared sensor, ultrasonic sensor, and DSM driver behavior camera and the input end of the signal relay device, as well as the output end of the signal relay device and the input end of the display device are all connected through the CAN bus. Since the forklift has a controller, an instrument, and a battery BMS module on the CAN bus network, the distance between nodes is within 5 meters, and the length of the entire CAN network harness is between several meters and tens of meters. Compared with passenger cars and commercial vehicles, there is less signal interference and the length is much shorter than the above vehicles. Considering the comprehensive cost and meeting the functional requirements, the CAN bus data transmission rate of this embodiment is 125Kbps. The use of the CAN bus ensures transmission efficiency and can save wiring harnesses. It is a widely used technology.

[0029] Furthermore, in this embodiment, the priority of some signals on the bus is shown in Table 1:

[0030]

[0031] Table 1

[0032] Among them, taking into account the priority of the forklift's operating safety and safety importance, the infrared sensor alarm is set to normal priority, because the infrared sensor will output an alarm to the signal relay device only when the alarm condition is met. If the infrared sensor has a high sensitivity, it will send a signal when it is powered on during the forklift's use. The CAN bus load rate will be too high, which will affect the information interaction processing of the forklift's motor controller, battery and other network node devices; the ultrasonic sensor sends a signal when it is powered on, because the signal is also used to display the forklift's real-time position, and the ultrasonic sensor signal is set to normal priority; the frequency of the driver making phone calls and dozing off is significantly lower than the other two sensors, and the time required to cause an accident is significantly longer, so the priority is set to low.

[0033] Furthermore, although the infrared sensor and the ultrasonic sensor have the same normal priority, when the infrared sensor and the ultrasonic sensor output alarm signals at the same time, the alarm signal of the infrared sensor is output first, and human safety is the first priority. That is, when people and obstacles appear within the working range of the forklift at the same time, human safety is prioritized to reduce the occurrence of safety accidents.

[0034] Furthermore, the signal relay device is used to convert the signals transmitted by components such as sensors and cameras. In this embodiment, the signal relay device assembles a complete frame for the infrared sensor according to the standard frame format, and sends it to the bus network according to the agreed CANID, data length, alarm byte, alarm content, and check code; assembles a complete frame for the ultrasonic sensor according to the standard frame format, and sends it to the bus network according to the agreed CANID, data length, obstacle distance, camera information, and check code; and also sends the CANID, data length, alarm content and distance, and alarm type to the bus network in the standard frame format for the DSM camera. The signal relay device converts the alarm signal output by the detection device and assembles it into a corresponding message and then outputs it to the display device. The signal relay device ensures the accuracy and security of the data.

[0035] Furthermore, the display device adopts an Internet of Things screen, which can realize real-time updating and personalized display of information, and improve the efficiency of human-computer interaction. The input end of the Internet of Things screen is connected to the output end of the signal relay device. The Internet of Things screen includes a memory, a controller, and a communication module. The memory is used to record alarm information, and the alarm information includes the time, category, and serial number of the alarm event; the controller is used to send a control signal according to the output of the signal relay device to control the Internet of Things screen to display pictures and texts and the sound and light prompt device to perform sound and light prompts; the communication module includes GPS and 4G LTE signal communication devices for communicating with the server. Based on the various components of the above-mentioned Internet of Things screen, when the historical records need to be called later in this embodiment, the data recorded in the memory can be quickly queried. At the same time, with the help of the GPS and 4G LTE signal devices built into the Internet of Things screen, the server background of the general controller can query the real-time alarm situation, and can be linked to push text messages. As an expansion, the Internet of Things screen can also make voice alarms based on the alarm signal. As a medium for human-computer interaction, the Internet of Things screen has improved the intelligence and digitization level of forklifts and improved the driver's operating experience

[0036] like Figure 4 The figure shows the display of the IoT screen page of this embodiment. When the IoT screen does not receive the alarm signal of the red sensor, the IoT screen displays "No abnormality"; when the IoT screen does not receive the heartbeat message signal of the red sensor, the IoT screen displays "Communication interrupted"; when the IoT screen receives the alarm signal of the red sensor, the IoT screen displays "Infrared camera alarm" and provides sound and light prompts through prompt path B.

[0037] When the IoT screen does not receive the alarm signal of the ultrasonic sensor, the IoT screen displays the real-time distance between the forklift and the obstacle; when the IoT screen does not receive the heartbeat message signal of the ultrasonic sensor, the IoT screen displays "communication interrupted"; when the IoT screen receives the alarm signal of the ultrasonic sensor, the IoT screen displays "specific number camera alarm" and the specific location of the obstacle, and provides sound and light prompts through prompt path B.

[0038] When the IoT screen does not receive the alarm signal from the DSM driver behavior camera, the IoT screen displays "No abnormality". When the IoT screen does not receive the heartbeat message signal from the DSM driver behavior camera, the IoT screen displays "Communication interrupted". When the IoT screen receives the alarm signal from the DSM driver behavior camera, the IoT screen displays different prompts according to the driver's dozing or phone call behavior, and performs sound and light prompts through prompt path B. This embodiment is based on human-computer interaction. When the forklift driver is at risk of overturning due to line of sight obstruction, cargo obstruction, etc., the forklift can be safely operated according to the display device and the sound and light prompt device to ensure safety and improve work efficiency. At the same time, based on the alarm signals of different sensors, the driver can obtain different safety warning information displayed on the IoT screen, avoid danger in time, and ensure personnel safety.

[0039] 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. A safety warning system for an electric forklift, characterized in that: The system includes a detection device, a signal relay device, a display device, and an audio-visual prompt device, wherein the output end of the detection device is connected to the input end of the signal relay device; the output end of the signal relay device is connected to the input end of the display device, and the output end of the display device is connected to the input end of the audio-visual prompt device.

2. The safety warning system for an electric forklift according to claim 1, characterized in that: The output end of the detection device is connected to the input end of the sound and light prompting device.

3. A safety warning system for electric forklift according to claim 1 or 2, characterized in that: The detection device includes an infrared sensor, an ultrasonic sensor, and a DSM driver behavior camera. The output ends of the infrared sensor, ultrasonic sensor, and DSM driver behavior camera are respectively connected to the input end of the signal relay device, wherein the infrared sensor is used to output an alarm signal when a person is detected within a dangerous range; the ultrasonic sensor is used to output a detection signal of the real-time position of the forklift, and output an alarm signal when an obstacle is detected within the dangerous range; the DSM driver behavior camera is used to output an alarm signal when abnormal driving behavior of the driver is detected, and the abnormal driving behavior includes the driver dozing off or making phone calls.

4. The safety warning system for an electric forklift according to claim 3, characterized in that: When the infrared sensor and the ultrasonic sensor output alarm signals at the same time, the alarm signal of the infrared sensor is outputted preferentially.

5. The safety warning system for an electric forklift according to claim 3, characterized in that: The output ends of the infrared sensor, ultrasonic sensor, and DSM driver behavior camera and the input end of the signal relay device, as well as the output end of the signal relay device and the input end of the display device are all connected via a CAN bus.

6. The safety warning system for an electric forklift according to claim 5, characterized in that: The CAN bus data transmission rate between the infrared sensor, ultrasonic sensor, DSM driver behavior camera and the signal relay device is 125Kbps.

7. The safety warning system for an electric forklift according to claim 1, characterized in that: The display device is an Internet of Things screen, and the input end of the Internet of Things screen is connected to the output end of the signal relay device.

8. The safety warning system for an electric forklift according to claim 7, characterized in that: The IoT screen includes a memory, a controller, and a communication module. The memory is used to record alarm information, and the alarm information includes the time, category, and serial number of the alarm event. The controller is used to send a control signal to control the IoT screen to display graphics and text and the sound and light prompt device to provide sound and light prompts based on the output of the signal relay device. The communication module includes GPS and 4G LTE signal communication devices for communicating with the server.

9. The safety warning system for an electric forklift according to claim 2, characterized in that: The detection device is used to detect the state of the forklift and the driver's behavior, and output an alarm signal when a dangerous situation occurs, wherein the dangerous situation includes a person or an obstacle within the safety range of the forklift, and abnormal driver behavior; The signal relay device is used to convert the alarm signal output by the detection device and assemble it into a corresponding message and then output it to the display device; The display device is used to verify and process the message output by the signal relay device, and then send a control signal to control the display device to display pictures and texts, and control the sound and light prompt device to perform sound and light prompts; When the display device fails, the sound and light prompt device is used to directly provide sound and light prompts according to the alarm signal output by the display device.

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