Forklift 3D Camera Mapping for Warehouse Storage Positioning

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Solution Overview

Problem

Existing methods for determining the positions of storage locations in warehouses rely heavily on manual processes, which are labor-intensive and require significant effort, especially in large warehouses, and do not allow for automatic updates or corrections.

Innovation Solution

The method employs an industrial truck equipped with a positioning system and lateral 3D cameras that capture image data to automatically determine and store the positions of storage locations in a database, using depth information and coordinate transformations to achieve precise location mapping, allowing for efficient and automated recording and optimization of storage locations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual detection of storage location positions is used, then the positions can be recorded, but the effort and time required are very high

Engineering Contradiction:

Improveposition accuracyVSAvoidteaching time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical positioning and measurement with an automated optical measurement system. The industrial truck is equipped with cameras and laser scanners that automatically capture images and measure distances to storage locations, eliminating the need for manual approach and measurement while maintaining high position accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service by allowing the industrial truck to automatically determine and record its own position relative to storage locations using onboard sensors and cameras. The truck independently performs the teaching function without requiring external manual intervention, significantly reducing the time and effort required.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual teaching is used to record storage location positions, then the positions can be stored, but changes to warehouse structure require additional manual intervention

Engineering Contradiction:

Improvewarehouse structure adaptabilityVSAvoidoperation complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system transitions from a static manual teaching process to a dynamic automated system. The industrial truck continuously captures images and measures positions using onboard sensors, allowing the system to automatically adapt to warehouse structure changes without requiring manual re-teaching. The dynamic nature of the automated system enables flexible response to structural modifications.

Inventive Principle:

Principle #15Dynamics

3Productivity

If automated positioning systems with cameras are used, then the effort for recording positions is reduced, but the system complexity increases

Engineering Contradiction:

Improveposition recording efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The industrial truck serves multiple functions: it performs material handling operations and simultaneously executes the teaching function for position recording using its onboard cameras and sensors. This multi-functionality allows the system to achieve automated position recording without adding dedicated complex equipment, as the truck's existing infrastructure is utilized for dual purposes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach significantly reduces the effort required for recording storage locations, enables automatic and precise determination of positions, and allows for continuous updates, improving the accuracy and efficiency of warehouse management without the need for manual intervention.

Implementation Method 1

In one configuration, the at least one lateral 3D camera is a time-of-flight camera. A time-of-flight camera has a light source and a light sensor, with the light source emitting modulated, in particular pulsed light which, after reflection from the objects in the image field, is emitted through a light entry opening onto a large number of pixels of the light sensor

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Data Source

PatentEP3323770B1Method for providing the positions of storage areas in a warehouse and an industrial truck

Publication Date: 2021.10.27 JUNGHEINRICH AG

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AI summary

Method for providing the positions of storage locations in a warehouse having a number of predetermined storage locations, using a forklift truck having a positioning system and at least one lateral 3D camera (34) whose viewing direction is oriented transversely to a main direction of travel, wherein the method comprises the following automatically executed steps: • Acquiring image data with the at least one lateral 3D camera, • Acquiring position information of the forklift truck with the positioning system, • Determining the positions of individual storage locations in a warehouse-fixed coordinate system based on the image data and position information, • Storing the determined positions in a database (22).