Floor Conveyor Remote Control Collision Avoidance
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Solution Overview
Problem
Existing floor conveyors in warehouses and distribution centers lack secure remote control operation capabilities, as they often require on-board controls and lack reliable object detection systems to prevent collisions, which can lead to operational inefficiencies and safety hazards.
Innovation Solution
A method and system that utilize a sensor device mounted on a floor conveyor to detect objects within a predetermined zone, allowing for secure remote operation by extending the detection zone and implementing safety measures such as shutdowns if objects are not detected, and using a single laser sensor for comprehensive area coverage, enabling autonomous operation with high security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If remote control operation is implemented without on-board controls, then operator convenience and productivity are improved, but operational safety and control reliability deteriorate
Solution Approach 1:
A remote control unit serves as an intermediary between the operator and the floor conveyor, allowing the operator to control the conveyor from a safe distance while maintaining full operational control through wireless communication
Solution Approach 2:
The system performs preliminary safety checks by extending the detection zone before operation and continuously monitoring objects in the travel path, ensuring safety measures are in place before remote operation begins
2Reliability
If detection zone is extended to improve safety coverage, then collision avoidance capability is improved, but sensor complexity and cost increase
Solution Approach 1:
The detection zone is extended in the spatial dimension by increasing the detection distance, allowing a single sensor to cover a larger area without adding more sensors, thus maintaining simplicity while improving coverage
Solution Approach 2:
The sensor device performs multiple functions including object detection, distance measurement, and collision prevention within an extended detection zone, reducing the need for additional specialized sensors
3Reliability
If complete shutdown is implemented when objects are not detected, then safety is improved, but operational flexibility and productivity deteriorate
Solution Approach 1:
The system dynamically adjusts operational modes based on detection results, allowing complete shutdown when safety is compromised but enabling continued operation in manual mode when the operator assumes responsibility, optimizing both safety and productivity
4Measurement precision
If multiple sensors are used to improve detection accuracy, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The system improves detection accuracy by changing parameters of a single sensor including increasing detection distance, adjusting detection sensitivity, and optimizing the detection zone configuration rather than adding multiple sensors
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables secure and efficient remote operation of floor conveyors by ensuring collision avoidance and maintaining high operational safety through automatic detection and response systems, even when objects are not detected within the initial zone, allowing operators to continue tasks without on-board controls.
Implementation Method 1
a sensor device (2) for detecting objects (4) inside a predetermined zone (5) outside at least a section of the circumference of the floor conveyor (1)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Method for operation of a floor conveyor, provided with a sensor device, comprising the steps of: a) provide a predetermined detection zone outside at least a section of the circumference of the floor conveyor for detection of foreign objects positioned inside the predetermined detection zone, wherein the predetermined detection zone is arranged to end at a first predetermined distance from a predetermined object, b) extend the predetermined detection zone with a second predetermined distance within which the predetermined object is expected to be positioned, c) implement security measures on to the floor conveyor, if the predetermined object is not detected within the extended predetermined detection zone. The present invention also relates to a of floor conveyor (1) comprising a sensor device (2) and a control unit (3) that can execute the method by means of a claimed computer executable software.