Fork-Tip LIDAR Layout for Pallet Detection and Alignment
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Solution Overview
Problem
Current sensing systems on pallet trucks and AGVs face challenges in accurately identifying and engaging pallets due to shadowing by fork bodies and debris, which can lead to false obstructions, limiting their ability to handle pallets at various orientations and positions.
Innovation Solution
The integration of LIDAR sensors within the fork tips, oriented parallel or tilted relative to the ground plane, to collect sensor data and process it using a processor for accurate pallet identification and orientation determination, enabling the vehicle to align forks with pallets effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If sensors are placed on the backplate of the pallet truck, then there is ample room for sensor placement, but the fork bodies shadow the sensor's view and debris can block the sensors causing false obstructions
Solution Approach 1:
The sensor system is segmented into multiple sensors distributed across different locations (backplate and fork tips) rather than relying on a single sensor location. This segmentation allows each sensor to cover specific zones, collectively providing comprehensive pallet detection without shadowing issues.
Solution Approach 2:
The sensor placement moves from a two-dimensional backplate surface to a three-dimensional distribution across the fork structure (backplate, fork tips, and along fork lengths). This spatial distribution in multiple dimensions eliminates shadowing by ensuring at least one sensor has an unobstructed view of the pallet from various angles.
2Measurement precision
If sensors are placed on the fork tips, then shadowing by fork bodies is eliminated, but the available space for sensor installation is limited
Solution Approach 1:
The fork structure is segmented into multiple sensor zones (backplate area, fork tip areas, and intermediate fork surfaces). Each segment can host sensors appropriate to its spatial characteristics, maximizing the use of limited surfaces while maintaining detection accuracy.
Solution Approach 2:
The fork structure serves dual functions: as the mechanical engagement component for pallets and as the mounting structure for the sensor system. This multi-functionality integrates the sensing capability directly into the existing fork geometry without requiring additional space.
3Device complexity
If traditional sensing systems are used, then the system structure is simple, but the ability to handle pallets at various orientations and positions is limited
Solution Approach 1:
The sensor system transitions from a static, fixed-orientation sensor arrangement to a dynamic multi-angle sensing capability. Multiple sensors positioned at different orientations on the fork structure enable detection of pallets in various positions and orientations, making the system adaptable to diverse warehouse scenarios.
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
This solution enhances the accuracy and flexibility of pallet engagement by distinguishing pallets from obstacles and adapting to pallets at different orientations, improving the efficiency of pallet transport systems in warehouse environments.
Implementation Method 1
The at least one sensor is coupled to at least one fork tip and is configured to collect sensor data representing structures and voids of at least one pallet
Data Source
AI summary
A transport vehicle, such as a vision guided vehicle, can comprise a drive portion constructed to facilitate movement of the transport vehicle and a load portion constructed to engage an object of interest. The load portion can comprise an object engagement apparatus and at least one sensor coupled to or disposed within a distal end of the object engagement apparatus, wherein the sensor can be at least a 2D sensor. The engagement apparatus can comprise forks, at least one fork having sensor coupled to or disposed within a fork tip. The 2D sensor can comprise a scanning LIDAR sensor arranged to collect information to identify a pickable pallet, for example.