MODE-CHANGE METHOD AND DEVICE FOR A MATERIAL HANDLING VEHICLE

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 429,911 filed December 2, 2022, and U.S. Provisional Patent Application No. 63 / 423,686 filed November 8, 2022.BACKGROUND

[0002] Warehouses typically employ the use of material handling vehicles, specifically, operators may use a remote control device to control travel of a material handling vehicle within the warehouse.

[0003] In addition, for certain types of vehicles there are training requirements imposed by various government agencies, laws, rules, and regulations. For example, OSHA imposes a duty on employers to train and supervise operators of various types of material handling vehicles. Recertification every three years is also required. In certain instances, refresher training in relevant topics shall be provided to the operator when required. In all instances, the operator remains in control of the material handling vehicle during performance of any actions. Further, a warehouse manager remains in control of the fleet of material handling vehicles within the warehouse environment. The training of operators and supervision to be provided by warehouse managers requires among other things proper operational practices including among other things that an operator remain in control of the material handling vehicle, pay attention to the operating environment, and always look in the direction of travel.

[0004] Document WO 2019 / 181664 A1 discloses a remote operation system for a forklift remotely operated by a remote operation device. The forklift is equipped with a manned operation sensor. A vehicle CPU when an occupant is detected by the manned operation sensor while movement of the forklift is being performed through remote operation by the remote operation device, performs remote operation stop control for stopping the remote operation and movement stop control for stopping the movement, regardless of operation of the vehicle operation unit.

[0005] Document US 2022 / 269262 A1 discloses a method for wireless communication between a wireless remote controlled device comprising a peripheral device and a controller on a material handling vehicle comprising a central device. The material handling vehicle may be provided with a presence sensor.BRIEF SUMMARY

[0006] The following presents a simplified summary of the disclosed technology herein in order to provide a basic understanding of some aspects of the disclosed technology. This summary is not an extensive overview of the disclosed technology. It is intended neither to identify key or critical elements of the disclosed technology nor to delineate the scope of the disclosed technology. Its sole purpose is to present some concepts of the disclosed technology in a simplified form as a prelude to the more detailed description that is presented later.

[0007] The present disclosure relates generally to material handling vehicles and, more specifically, to remotely controllable material handling vehicles that can be switched between a manual mode and a remote mode.

[0008] In one aspect, the present disclosure describes a method of transitioning a material handling vehicle between a manual mode and a remote mode. The method includes automatically transitioning the material handling vehicle from the remote mode to the manual mode in response to a determination, by a floor mat circuit, that an operator is positioned within an operator compartment of the material handling vehicle, preventing entering the remote mode while the floor mat circuit indicates that the operator is positioned within the operator compartment, manually actuating a mode selection switch, positioned on the material handling vehicle, from a first position to a second position and back to the first position, and permitting entering the remote mode after the floor mat circuit ceases to indicate that the operator is positioned within the operator compartment. Further, the method includes displaying a status message in response to the closure of the floor mat circuit, the status message to remain displayed once the operator leaves the operator compartment; preventing entering the remote mode while the status message is active; clearing the status message from the display by manually actuating a mode selection switch, from a first position to a second position and back to the first position; and permitting entering the remote mode after status message has been cleared.

[0009] In another aspect, the present disclosure describes a system for transitioning a material handling vehicle between a manual mode and a remote mode. The system includes one or more mode selection switches configured to transition the material handling vehicle from the manual mode to the remote mode, a floor mat circuit positioned within an operator compartment of the material handling vehicle, the floor mat circuit configured to provide a signal to the material handling vehicle to exit the remote mode and enter the manual mode when the floor mat circuit determines an operator is within the operator compartment while the material handling vehicle is in the remote mode, and a display positioned within the operator compartment of the material handling vehicle, the display configured to depict a status message when the floor mat circuit provides a signal to the material handling vehicle when the floor mat circuit determines the operator is within the operator compartment while the material handling vehicle is in the remote mode. In one example, actuation of the one or more mode selection switches from a first position to a second position and back to the first position clears the status message from the display and permit the material handling vehicle to enter the remote mode.

[0010] In another aspect, the present disclosure describes a method of transitioning a material handling vehicle between a manual mode and a remote mode. The method includes operating the material handing vehicle in the remote mode in response to a travel request from a remote control device in communication with the material handling vehicle. The method further includes automatically transitioning the material handling vehicle from the remote mode to the manual mode in response to a determination that a floor mat circuit of the material handling vehicle has transitioned from one state to another state, displaying a status message on a display of the material handling vehicle, clearing the status message from the display by actuation of one or more mode selection switches, and upon the determination that the status message is cleared, the material handling vehicle reentering the remote mode.

[0011] The foregoing and other aspects and advantages of the disclosure will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred configuration of the disclosure. Such configuration does not necessarily represent the full scope of the disclosure, however, and reference is made therefore to the claims and herein for interpreting the scope of the disclosure.BRIEF DESCRIPTION OF DRAWINGS

[0012] The present disclosure will be better understood and features, aspects, and advantages other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings. Fig. 1 is a perspective view of a non-limiting example of a material handling vehicle according to aspects of the present disclosure. Fig. 2 is a side view of the material handling vehicle of Fig. 1. Fig. 3 is a diagrammatic view of a system for remotely controlling the material handling vehicle of Fig. 1. Fig. 4 is perspective view of an example arrangement of one or more mode selection switches of Fig. 3 for use with the material handling vehicle of Fig. 1. Fig. 5 is perspective view of another example arrangement of the one or more mode selection switches of Fig. 3 for use with the material handling vehicle of Fig. 1. Fig. 6 is perspective view of another example arrangement of the one or more mode selection switches of Fig. 3 for use with the material handling vehicle of Fig. 1. Fig. 7 is perspective view of another example arrangement of the one or more mode selection switches of Fig. 3 for use with the material handling vehicle of Fig. 1. Fig. 8 is a flow chart illustrating a mode transition process for the material handling vehicle of Fig. 1. Fig. 9 is a flow chart illustrating a remote mode reengagement process for the material handling vehicle of Fig. 1. DETAILED DESCRIPTION

[0013] Figs. 1 and 2 illustrate one non-limiting example of a material handling vehicle 100 according to the present disclosure. The material handling vehicle 100 may include a vehicle frame 102, a traction wheel 104, a power section 108, and an operator compartment 110. The power section 108 may be disposed within the vehicle frame 102 and may include a battery to supply power to various components of the material handling vehicle 100. For example, the battery may supply power to a motor and / or transmission disposed within the power section 108 and configured to drive the traction wheel 104. In the illustrated non-limiting example, the traction wheel 104 is arranged under the power section 108. In other non-limiting examples, the traction wheel 104 may be arranged in another location under the vehicle frame 102.

[0014] The operator compartment 110 may include a control handle 111 configured to provide a user interface for an operator and to allow the operator to control a speed and direction of travel of the material handling vehicle 100. In some non-limiting examples, the control handle 111 may be configured to manually steer and control power to the traction wheel 104. The control handle 111 can include a control handle switch 155, which can be used to determine if the control handle is in the down (e.g., operating) position, or if the control handle is in the upright (e.g., brake) position. In some embodiments, the control handle 111 can be a spring-loaded 157 control handle 111 and can be configured to default to a single position. For example, the control handle 111 can default into either the down (e.g., operating) position, as shown, or the upright (e.g., brake) position. In other embodiments, the spring loaded control handle 111 can be configured to default to more than one position. For example, the spring-loaded control handle can default to the position the spring-loaded control handle is closest to when released by an operator. In one particular example, the spring-loaded control handle is closest to the down position when released by the operator, so the spring-loaded control handle moves to the substantially down position due to the spring force. Correspondingly, when the spring-loaded control handle is closest to the upright position when released by the operator, the spring-loaded control handle moves to the substantially upright position due to the spring force. Other arrangements are also possible.

[0015] In the illustrated non-limiting example shown in Figs. 1 and 2, the material handling vehicle 100 includes the operator compartment 110 arranged rearward of the power section 108 and having an operator opening 112 that opens towards lateral sides 114 of the material handling vehicle 100. The operator compartment 110 may also contain a floor mat 116 on which an operator of the material handling vehicle 100 may stand. The floor mat 116 can also include a floor mat sensor 159, which can be used to determine when the material handling vehicle operator is in the operator compartment and positioned on the floor mat. The floor mat sensor 159 can be of known types including proximity, pressure, or weight, as non-limiting examples. In some non-limiting examples, the material handling vehicle 100 may be designed with the operator compartment arranged differently, for example, with an operator opening 112 that opens rearwardly. In the illustrated non-limiting example, the material handling vehicle 100 includes a pair of forks 118 that can be raised or lowered by actuators 161, e.g., as shown by arrow 163, in response to commands from the control handle 111.

[0016] Fig. 3 illustrates one non-limiting example of a remote control system 120 for a remotely controllable material handling vehicle, which may be implemented, for example, in the material handling vehicle 100 shown in Fig. 1. The remote control system 120 can be a modular system in that at least some of the elements that support the remote control function can be housed together in one or more housings that can be used to retrofit a material handling vehicle to allow the vehicle to operate in a remote control mode. The remote control system 120 includes a remote control device 122 in communication with the material handling vehicle 100. The remote control device 122 is operable by an operator of the material handling vehicle 100 and can include a travel control function 124 and an I / O function 126. The travel control function 124 and the I / O function 126 can be configured as first and second manually operable functions that can be operated by, for example, a button or a switch located on the remote control device 122. For example, the travel control function 124 can be operated by a first button 125 on the remote control device 122 and the I / O function 126 can be operated by a second button 127 on the remote control device 122. The travel control function 124 and the I / O function 126 can be in electrical communication with a transmitter 128 within the remote control device 122. The transmitter 128 on the remote control device 122 can wirelessly communicate with the material handling vehicle 100 by a receiver 130 located on the material handling vehicle 100, as represented by dashed line 132. In another example, the transmitter 128 and the receiver 130 may instead each be in the form of transceivers. In some non-limiting examples, the remote control device 122 may turn off after several minutes of inactivity.

[0017] It is to be appreciated that the travel control function 124, the I / O function 126, and other material handling vehicle functions, can also be activated using other systems. For example, the functions can be voice activated, gesture activated, floor / surface illumination system activated, and / or warehouse management system activated.

[0018] Referring now to Figs. 1-3, the material handling vehicle 100 can be configured to transition between a manual mode and a remote mode. In one non-limiting example, the material handling vehicle 100 can have one or more mode selection switches, which can include buttons or devices 151 (e.g., a manually operable multi-position switch or button, such as a rocker switch, toggle, momentary contact, push-pull, keyed, illuminated, etc.) that can be positioned within or near the operator compartment 110 for access by the operator of the material handling vehicle 100. The mode selection switches 151 may be used by an operator as a component of a mode selection process (e.g., a transition from manual mode to remote mode) of the material handling vehicle 100. For example, the mode selection switches 151 may be turned, actuated, moved, depressed, etc. to select a remote mode or a manual mode for the material handling vehicle 100. The mode selection switches 151 can be operable from a first position to a second position, and then back to the first position.

[0019] It is to be appreciated the switch or switches can be of any known type that are capable of changing from one state to another state, such as between at least one open position and one closed position, or a high state to a low state, as non-limiting examples. In other embodiments, the switch or switches may not transition between an open and closed position, and instead may be activated to change a state from one state to another state by proximity, pressure, and / or temperature, as non-limiting examples. For example, the mode selection switches 151 can be positioned on the control handle 111, next to a display 115, or on a control panel 117 and accessible by the operator. In another non-limiting example, the mode selection switches 151 can be positioned on the outside of the material handling vehicle 100. For example, the switches can be positioned on one or both of the lateral sides 114 or on the vehicle frame 102 of the material handling vehicle 100.

[0020] In another non-limiting example, the transition between a manual mode and a remote mode can be initiated by a travel request controller 144 upon a pairing of the remote control device 122 to the material handling vehicle 100, or upon activating the travel control function 124. In one non-limiting example, the travel request controller 144 may include a processor 171 configured to execute instructions stored on non-volatile memory 173. In one example, the processor may be configured to automatically transition the material handling vehicle from the remote mode into the manual mode in response to an indication that an operator is present within the operator compartment.

[0021] When the material handling vehicle 100 is in the manual mode, the material handling vehicle 100 can be operated normally by the operator. For example, the operator can use the control handle 111 on the material handling vehicle 100 to accelerate, decelerate, steer, or otherwise maneuver the material handling vehicle 100 manually by using a throttle or brake button / lever located on the control handle 111. In one non-limiting example, the control handle 111 may include one or more jog buttons 113 configured to, when engaged, cause the material handling vehicle 100 to travel at a walking speed. Upon release of the jog button 113, the material handling vehicle 100 may coast to a stop.

[0022] Looking to Figs. 4-7, various example arrangements of the mode selection switches 151 are shown. As should be appreciated, these example arrangements are merely non-limiting examples and other arrangements of the mode selection switches 151 are envisioned. As shown in Fig. 4, the mode selection switches 151 may include a first switch 305 and a second switch 310, which may be arranged on opposing sides of the control panel 117, within the operator compartment 110. As shown in Fig. 5, the mode selection switches 151 may include a first switch 405 and a second switch 410, which may be arranged on opposing sides 114 of the material handling vehicle 100. For example, the switches 405, 410 may be arranged on the frame 102 of the material handling vehicle 100 adjacent to the control panel 117 within the operator compartment 110. As shown in Fig. 6, the mode selection switches 151 may include a first switch 505 and a second switch 510, which may be arranged on the control panel 117 within the operator compartment 110. Looking now to Fig. 7, the mode selection switches 151 may include a first switch 605 and a second switch 610, which may be arranged on the frame 102 of the material handling vehicle 100 outside or remote from the operator compartment 110.

[0023] Thus, the mode selection switches 151 may be positioned anywhere on the material handling vehicle 100 that is convenient for an operator to reach, access, or actuate the switches 151. In some cases, only a single mode selection switch 151 may be used. In other cases, three or more mode selection switches 151 may be used and arranged around the material handling vehicle 100. As should be appreciated, the first switch 305, 405, 505, 605 and the second switch 310, 410, 510, 610 may be the same or similar in design, but merely arranged in different areas of the vehicle to facilitate ease of use or operation by the operator.

[0024] Fig. 8 shows a flowchart depicting a mode transition process 700 for the material handling vehicle 100. In particular, the process 700 shows an example of automatically transitioning the material handling vehicle 100 from the remote mode into the manual mode when the floor mat circuit has changed state (i.e., an operator is in the operator compartment). For example, when the material handling vehicle 100 is operating in the remote mode and an operator steps into the operator compartment, the floor mat circuit closes. It should be noted that the material handling vehicle 100 operates in the remote mode without monitoring a status of the floor mat circuit. Instead, the vehicle receives an input from the floor mat circuit only when an operator is within the operator compartment such that the floor mat circuit changes state (e.g., open to closed). When an operator is not within the operator compartment (i.e., the floor mat circuit remains open), the material handling vehicle 100 can operate in the remote mode.

[0025] Looking to the mode transition process 700, at stage 705, the material handling vehicle 100 is operating in the remote mode (e.g., a mode selection switch 151 has been actuated to indicate operation in the remote mode, and no operator is in the operator compartment 110). At stage 710, the floor mat circuit closes due to an operator stepping into the operator compartment 110, which causes the material handling vehicle 100 to automatically stop travel (if moving) at stage 715. Additionally, at stage 720, the material handling vehicle 100 automatically exits the remote mode and enters the manual mode of operation (even though a mode selection switch 151 has not been actuated).

[0026] At stage 725, the display 115 of the material handling vehicle 100 will depict a status message indicting that the remote mode was interrupted due to the detection of an operator in the operator compartment 110. The material handling vehicle 100 will continue to depict the status message on the display 115 and will not return or reenter the remote mode until, at stage 730, the mode selection switch 151 is actuated (e.g., toggled, pushed, switched, etc.). Once the mode selection switch 151 has been actuated at stage 730, the status message is cleared as shown at stage 735, which then enables an operator to restart or reengage the remote mode, if desired.

[0027] An example process for the material handling vehicle 100 to reenter the remote mode is shown in FIG. 9. As shown, to enable the material handling vehicle 100 to reenter the remote mode, the operator must disembark from the operator compartment 110 at stage 805. Put differently, the material handling vehicle 100 must no longer be receiving a signal that the floor mat switch is closed. Following this, at stage 810, the operator actuates the mode selection switch 151 to clear the status message on the display 115. However, in some embodiments, the mode selection switch may not need to be returned to a specific position (e.g., with a momentary contact push button). Following this, at stage 815, the operator may again actuate the mode selection switch 151 to allow the material handling vehicle 100 to reenter the remote mode and restart remote operator of the material handling vehicle 100. In some embodiments, the status of the control handle switch 155 can be used in place of the floor mat switch to allow or not allow transition between the manual mode and the remote mode.

[0028] The below example use cases depict examples of the mode transition process 700 and the remote mode reengagement process 800 in use. As should be appreciated, alternative or additional example use cases are envisioned.

[0029] Example Use Case 1 - The operator boards a stationary vehicle that is in the remote mode.

[0030] Upon determining that the floor mat circuit has changed state (i.e., the operator, pedestrian, or other person / object is in the operator compartment 110), the material handling vehicle 100 exits the remote mode (i.e., enters the manual mode), and displays a status message on the module display 115.

[0031] To reenter the remote mode, the mode selection switch 151 is actuated, e.g., moved to the "Manual Mode" position, and then returned to the "Remote Mode" position, with all other criteria to enter the remote mode also being satisfied.

[0032] Example Use Case 2 - The operator boards a moving vehicle that is in the remote mode.

[0033] Upon determining that the floor mat circuit has changed state (i.e., the operator, pedestrian, or other person / object is in the operator compartment 110), the material handling vehicle 100 stops, exits the remote mode (i.e., enters the manual mode), and displays a status message on the module display 115.

[0034] To reenter the remote mode, the mode selection switch 151 is actuated, e.g., moved to the "Manual Mode" position, and then returned to the "Remote Mode" position, with all other criteria to enter the remote mode also being satisfied.

[0035] Example Use Case 3 - The operator attempts to enter the remote mode while on the vehicle.

[0036] Upon determining that all criteria are met to enter the remote mode, the material handling vehicle 100 enters the remote mode, and immediately determines that the floor mat circuit is closed (i.e., the operator, pedestrian, or other person / object is in the operator compartment 110), the material handling vehicle 100 exits the remote mode (i.e., enters the manual mode), and displays a status message on the module display 115.

[0037] To reenter the remote mode, the mode selection switch 151 is actuated, e.g., moved to the "Manual Mode" position, and then returned to the "Remote Mode" position, with all other criteria to enter the remote mode also being satisfied.

[0038] Example Use Case 4 - The operator disembarks from a vehicle that is in the remote mode.

[0039] An operator will be unable to be on the material handling vehicle that is in the remote mode as described previously. If an operator is on the material handling vehicle 100 (i.e., in the operator compartment 110), the material handling vehicle 100 exits the remote mode and enters the manual mode.

[0040] Example Use Case 5 - The operator disembarks from a vehicle in the manual mode immediately after all criteria are met to enter the remote mode.

[0041] Upon determining that all criteria are met to enter the remote mode, if the floor mat circuit is still closed (i.e., the operator, pedestrian, or other person / object is in the operator compartment 110), the vehicle exits the remote mode (i.e., enters the manual mode), and displays a status message on the module display 115.

[0042] To reenter the remote mode, the mode selection switch 151 is actuated, e.g., moved to the "Manual Mode" position, and then returned to the "Remote Mode" position, with all other criteria to enter the remote mode also being satisfied.

[0043] Example Use Case 6 - The operator disembarks from a vehicle in the manual mode immediately prior to all criteria being met to enter the remote mode.

[0044] Should the operator disembark from the material handling vehicle 100 prior to the remote control system 120 determining that all criteria are met to enter the remote mode, the vehicle will enter the remote mode with an actuation of the mode selection switch 151 and permit remote operation of the material handling vehicle 100 using the remote control device 122.

Claims

1. A method of transitioning a material handling vehicle (100) between a manual mode and a remote mode, comprising: automatically transitioning the material handling vehicle (100) from the remote mode to the manual mode in response to, closure of a floor mat circuit, the closure of the floor mat circuit indicating the presence of an operator within an operator compartment (110) of the material handling vehicle (100); characterized in that displaying a status message in response to the closure of the floor mat circuit, the status message to remain displayed once the operator leaves the operator compartment (110); preventing entering the remote mode while the status message is active; clearing the status message from the display by manually actuating a mode selection switch (151), from a first position to a second position and back to the first position; and permitting entering the remote mode after status message has been cleared.

2. The method of claim 1, wherein the first position of the mode selection switch (151) corresponds to the remote mode.

3. The method of claim 1 or 2, wherein the second position of the mode selection switch (151) corresponds to the manual mode.

4. The method any of the claims above, wherein transitioning the material handling vehicle (100) from the remote mode to the manual mode automatically stops travel of the material handling vehicle (100).

5. The method of any of the claims above, further comprising: wherein the status message is depicted on a display (115) positioned within the operator compartment (110).

6. The method of claim 5, further comprising: preventing entering the remote mode while the status message is depicted on the display (115).

7. A system for transitioning a material handling vehicle (100) between a manual mode and a remote mode, comprising: one or more mode selection switches (151) configured to transition the material handling vehicle (100) from the manual mode to the remote mode; a floor mat circuit positioned within an operator compartment (110) of the material handling vehicle (100), the floor mat circuit configured to provide a signal to the material handling vehicle (100) to exit the remote mode and enter the manual mode when the floor mat circuit is closed, closure of the floor mat circuit corresponding to the presence of an operator within the operator compartment (110) while the material handling (100) vehicle is in the remote mode; and a display (115) positioned within the operator compartment (110) of the material handling vehicle (100), characterized in that the display (115) configured to depict a status message in response to closure of the floor mat circuit, and the display to continue to depict the status message once the operator is within the operator compartment (110); wherein the material handling vehicle is prevented from entering the remote mode when the status message is depicted on the display; and wherein actuation of the one or more mode selection switches (151) from a first position to a second position and back to the first position clears the status message from the display (115) and permits the material handling vehicle (100) to enter the remote mode.

8. The system of claim 7, wherein the first position of the one or more mode selection switches (151) corresponds to the remote mode.

9. The system of claim 7 or 8, wherein the second position of the one or more mode selection switches (151) corresponds to the manual mode.

10. The system of any of the claims 7 - 9, wherein the one or more mode selection switches (151) includes a first mode selection switch and a second mode selection switch.

11. The system of claim 10, wherein the first mode selection switch and the second mode selection switch are positioned on opposing sides of the operator compartment (110) of the material handling vehicle (100).

12. The system of any of the claims 10 - 11, wherein the first mode selection switch and the second mode selection switch are positioned outside of the operator compartment (110) of the material handling vehicle (100).