Autonomous Order Picking Truck with Obstacle Detection
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Solution Overview
Problem
Low level order picking trucks require significant operator time for relocating and repositioning, reducing the time available for actual stock picking due to the repetitive nature of the pick process.
Innovation Solution
A materials handling vehicle equipped with a power unit, load handling assembly, obstacle detectors, and a controller that adjusts speed based on load weight and detected obstacles, combined with a finger-mounted remote control device for wireless operation, allowing for autonomous navigation and reduced operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the operator manually relocates and repositions the order picking truck for each pick location, then the operator can directly control the truck movement, but the time available for actual stock picking is reduced
Solution Approach 1:
The order picking truck is equipped with autonomous navigation capabilities including obstacle detectors, load sensors, and controllers that enable the vehicle to automatically navigate to pick locations, return to home positions, and adjust speed based on load weight and detected obstacles without operator intervention for movement control
Solution Approach 2:
The manual mechanical control system is replaced with an automated electronic control system comprising obstacle detectors, load sensors, and a controller that uses sensor data to automatically adjust vehicle speed and navigation, substituting the operator's manual steering and speed control
2Productivity
If the operator spends considerable time relocating the truck between pick locations, then complete coverage of all stock items is achieved, but the overall order picking throughput decreases
Solution Approach 1:
The truck autonomously performs relocation tasks using its built-in navigation system, obstacle detection capabilities, and automatic speed adjustment features, eliminating the need for operator time investment in movement while maintaining complete coverage of all pick locations
Solution Approach 2:
The autonomous system enables continuous operation by automatically managing truck movement between pick locations without interruption to the picking process, allowing the operator to continuously pick stock while the system handles all relocation operations seamlessly
3Loss of time
If the vehicle travels at high speed to improve relocation efficiency, then time for relocation is reduced, but safety risks increase when loads are heavy or obstacles are present
Solution Approach 1:
Load sensors continuously measure the weight of loads on the truck and provide feedback to the controller, which automatically adjusts the maximum allowable speed based on the detected load weight, ensuring safety while maintaining efficient relocation
Solution Approach 2:
Obstacle detectors continuously scan the environment and provide feedback to the controller, which automatically reduces vehicle speed or stops the truck when obstacles are detected in the path of travel, maintaining safety while enabling high-speed operation in clear conditions
Data Source
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AI summary
A materials handling vehicle (10) comprising, a power unit (14), a load handling assembly (12) coupled to said power unit (14), at least one first obstacle detector (76, 76A, 76B) mounted at a first location on said power unit (14) to detect an object located along a path of travel of said power unit (14) beyond a dead zone (DZ) of said first detector (76, 76A, 76B), and at least one second obstacle detector (76, 76A, 76B) mounted at a second location on said power unit (14), spaced from said power unit first location, and capable of detecting an object in said dead zone (DZ) of said first obstacle detector (76, 76A, 76B).