Fork Tip ToF Camera for Industrial Truck Positioning
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Solution Overview
Problem
Industrial trucks face challenges in accurately positioning pallets during storage and retrieval due to limited visibility and the need for experienced operators, especially at high stacking heights, leading to difficulties in estimating lateral distance and depth, which complicates the process and requires complex systems for fully automatic solutions.
Innovation Solution
An industrial truck equipped with a time-of-flight camera system having a light source and sensor integrated into the fork tips, allowing for three-dimensional environment detection and precise positioning, along with an evaluation unit that provides instructions to the operator for collision-free operations, supporting both manual and automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a video camera system is used to support the operator, then the operator can see the stacking process, but the operator still cannot accurately estimate lateral distance and depth to other pallets and shelf posts
Solution Approach 1:
The patent transitions from 2D video imaging to 3D spatial measurement by integrating multiple sensors (laser distance sensors, ultrasonic sensors, RFID readers) that provide depth and distance information in the third dimension, enabling accurate measurement of lateral distances and depths to pallets and shelf posts
Solution Approach 2:
The patent introduces an intermediary evaluation unit that processes sensor data and generates guidance instructions, acting as a mediator between the raw sensor information and the operator's control actions, thereby improving measurement precision through computational processing
2Measurement precision
If fully automatic storage or retrieval systems are implemented, then positioning accuracy is improved, but the system complexity and cost increase significantly
Solution Approach 1:
The patent creates a multi-functional sensor system where a single integrated evaluation unit processes data from multiple sensor types (optical, ultrasonic, RFID) to perform various functions including distance measurement, position detection, and guidance generation, reducing overall system complexity while maintaining high positioning accuracy
Solution Approach 2:
The system provides self-service through automated sensor-based detection and evaluation that generates guidance instructions without requiring complex external control systems or manual intervention, enabling the truck to autonomously determine its position and receive positioning assistance
3Ease of operation
If the operator remains on the vehicle at ground level, then the operator can control the truck, but the operator's view of the actual stacking process is limited by distance and angle
Solution Approach 1:
The patent uses sensor systems and evaluation units as intermediaries that capture environmental data and translate it into actionable guidance information, compensating for the operator's limited visual perspective while maintaining ground-level operation and control
Solution Approach 2:
The patent replaces the mechanical requirement for direct visual observation with an electronic sensor-based information system that provides spatial awareness through processed sensor data and guidance instructions, eliminating the need for the operator to have direct line-of-sight to the stacking point
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
Enhances operator support by providing precise positioning and collision avoidance, improving the efficiency and safety of storage and retrieval processes, and enabling flexible and reliable operation from manual to semi- or fully automated modes.
Implementation Method 1
The sensor has a time-of-flight camera system with a light source, a light sensor and a light entry opening
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Industrial truck with a lifting frame (3) on which a load carrier with two fork tines (4) is guided in a height-adjustable manner, a sensor arranged on the load carrier for detecting a spatial environment and an evaluation unit (6) which is designed to determine a storage position from the data detected by the sensor in order to support a storage process, wherein the sensor has a time-of-flight camera system (5) with a light source (23), a light sensor (22) and a light inlet aperture, wherein at least the light inlet aperture is arranged in the area of a tip of one of the fork tines.