Forklift Camera Integration for Code Scanning and Fork Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Forklift truck operators face inefficiencies in merchandise identification and pallet fork alignment due to limited visibility in dark warehouse environments and obstructed views, requiring repetitive adjustments and external verification tools.
Innovation Solution
A multi-function camera system with a camera device, fill light module, and image processing unit is integrated into the forklift, enabling optical identification code scanning, providing multi-color illumination, and assisting pallet fork alignment through visual or radar positioning on a display screen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a camera device is installed on the forklift to assist observation, then the operator can observe the pallet fork and merchandise, but the operator still cannot observe clearly in dark warehouse environments without additional lighting
Solution Approach 1:
The patent combines the fill light module with the camera device into an integrated unit. The fill light module includes multiple light sources (white light source, yellow light source, blue light source, infrared light source) that are physically integrated with the camera lens, allowing simultaneous illumination and image capture without requiring separate lighting equipment. This resolves the contradiction by merging lighting functionality into the existing observation system.
Solution Approach 2:
The fill light module is designed to provide multiple colors of light (white, yellow, blue, infrared) to serve different observation needs. The system can switch between different light colors depending on the situation, making a single device capable of multiple functions - both illumination and various types of merchandise observation, thereby improving lighting brightness without proportionally increasing system complexity.
2Productivity
If the operator uses other instruments to verify merchandise content, then accurate information can be obtained, but operation efficiency decreases due to repetitive adjustments and time consumption
Solution Approach 1:
The system enables automatic optical identification code scanning by the camera device. The identification module automatically detects and reads barcode or QR code information from merchandise without requiring the operator to manually use separate verification instruments. The system serves itself by autonomously capturing and processing identification information, thereby improving operation efficiency while maintaining accurate merchandise information accessibility.
Solution Approach 2:
The patent replaces manual mechanical verification processes with an automated optical recognition system. Instead of the operator physically handling merchandise to read codes or use separate verification tools, the camera device with integrated optical recognition capabilities automatically scans and identifies merchandise information optically, substituting manual mechanical verification with automated optical detection to improve productivity.
3Measurement precision
If the operator makes repetitive adjustments to align with the pallet, then proper alignment can be achieved, but operation time increases and efficiency decreases
Solution Approach 1:
The camera device provides real-time visual feedback to the operator by capturing and displaying images of the pallet fork and surrounding area. The operator can see the current alignment status through the camera view and make precise adjustments based on this feedback, reducing the number of repetitive adjustments needed. This feedback mechanism enables faster and more accurate alignment by allowing the operator to visually assess positioning in real-time.
Solution Approach 2:
The system adds a visual dimension to the alignment process by introducing camera-based observation. Instead of relying solely on direct line-of-sight visual alignment, the operator gains an additional dimensional perspective through the camera feed, which can be viewed from the operator's position. This extra observational dimension enables more precise alignment judgments and reduces the time required for repetitive adjustment cycles.
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 operation efficiency by allowing direct merchandise information retrieval, improving alignment precision, and ensuring safety with enhanced lighting and visual aids, thereby simplifying the forklift truck operation.
Implementation Method 1
the fill light module is used for providing at least one color of illumination light in a shooting direction of the camera lens
Implementation Method 2
the camera lens is used for shooting a real image in front of the forklift truck
Implementation Method 3
the camera device further comprises a laser head for projecting an auxiliary positioning laser beam toward a front thereof
Data Source
AI summary
A multi-function camera system, applied to a forklift truck, includes a camera device and a display device installed on the forklift truck, and an image processing unit coupled between the camera device and the display device, capable of shooting and displaying a corresponding real image in order to assist operations of the forklift truck. In addition, the camera device is equipped with a fill light module capable of providing multiple light colors, and the image processing unit includes an identification module capable of identifying the optical identification code. Accordingly, the camera system with multiple functions of monitoring, fill light, identification and positioning etc. is achieved.