Fork-Mounted Camera for High-Bay Rack Label Recognition
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Solution Overview
Problem
Current industrial truck operations in high-bay warehouses face challenges in accurately scanning pallet labels at great heights, leading to errors in storing goods in incorrect locations due to the limitations of manual scanning with hand scanners and close spacing of barcode labels.
Innovation Solution
Equipping an industrial truck with a digital camera on a fork prong to capture and analyze digital image data of rack bay labels, including barcodes and clear text, which are then displayed on a screen for the operator, allowing for automated scanning and transmission to warehouse management software, eliminating the need for manual scanning and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual hand scanners are used to scan pallet labels at great heights, then the scanning capability is limited, but scanning accuracy deteriorates and errors increase
Solution Approach 1:
The patent replaces manual hand-held barcode scanners with an automated optical scanning system. A camera mounted on the fork carrier captures images of rack bay labels, and an image processing unit automatically recognizes and processes the barcode information. This substitution eliminates manual scanning operations while improving scanning accuracy through automated image analysis.
Solution Approach 2:
The system performs self-service scanning by automatically capturing, processing, and recognizing barcode labels without requiring operator intervention. The camera autonomously acquires label images, the processing unit extracts barcode data, and the system integrates this information with warehouse management software, freeing operators from manual scanning tasks.
2Productivity
If barcodes are mounted on storage racks at high positions, then storage capacity is improved, but scanning reliability deteriorates due to closely spaced labels
Solution Approach 1:
The patent replaces manual scanning with automated optical recognition. The camera captures high-resolution images of closely spaced barcodes on rack bays, and the image processing unit uses computer vision algorithms to distinguish and recognize individual barcodes even when closely positioned. This automated approach reliably identifies correct rack bay labels that would be difficult to scan manually.
Solution Approach 2:
The system transitions from one-dimensional manual scanning to two-dimensional image capture and processing. By capturing the entire label field as an image and processing it computationally, the system can distinguish between closely spaced barcodes based on their spatial positions and visual characteristics, improving reliability in high-density storage environments.
3Speed
If automated digital camera scanning is implemented, then scanning speed is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single unified system. The camera serves both as a documentation device and a scanning device. The image processing unit simultaneously performs barcode recognition, label identification, and data extraction. This multi-functional integration achieves fast automated scanning while managing system complexity through consolidated hardware and software components.
Solution Approach 2:
The patent merges the scanning function with the existing fork carrier structure. The camera is mounted on the fork carrier, combining the lifting mechanism's positioning capability with the scanning function. This integration eliminates the need for separate scanning hardware and reduces overall system complexity while maintaining high scanning speed through automated operation.
4Reliability
If digital image capture and analysis is used, then error reduction is achieved, but processing time increases
Solution Approach 1:
The system performs preliminary image capture during the normal forklift operation cycle. As the fork carrier moves to position pallets, the camera automatically captures label images without requiring separate scanning actions. The image processing occurs concurrently with positioning operations, reducing the perception of processing time while maintaining high accuracy through thorough image analysis.
Data Source
AI summary
The invention relates to a method for operating an industrial truck (10), the industrial truck (10) comprising a lifting mechanism (12), a fork carrier comprising two fork prongs (16) being height-adjustably guided on the lifting mechanism (12), a preferably individual rack bay label (31, 32, 33) provided on a rack bay (F1, F2, F3) of a storage rack (30), particularly a high-bay storage rack, is captured as digital image data by means of a digital camera (18) disposed on a fork prong (16) or on the fork carrier, the digital images being preferably transmitted from the digital camera (18) to a computer unit (22) of the industrial truck (10), wherein the digital image data is analyzed by the computer unit (22) and transmitted after the analysis to a display panel of the industrial truck (10), particularly a display unit (24), and information corresponding to the captured rack bay label (31, 32, 33) of the rack bay (F1, F2, F3), particularly text information and/or symbols, is displayed on the display panel of the industrial truck (10).