Forklift Camera With Fill Light and Laser Fork Alignment
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Solution Overview
Problem
Forklift truck operators face inefficiencies in merchandise identification and pallet fork alignment due to limited visibility in dark warehouse environments, where current camera systems fail to provide adequate illumination and precise positioning assistance.
Innovation Solution
A multi-function camera system with a camera device, fill light module, and image processing unit that includes an identification module for scanning optical codes and providing merchandise information, along with a laser positioning system for aligning the pallet fork, enhancing visibility and safety through different color illumination and visual aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a camera system is installed on the forklift truck to assist observation, then the operator can view the pallet fork and surrounding area, but the system fails to provide adequate illumination in dark warehouse environments
Solution Approach 1:
The patent combines the camera system with a fill light module into an integrated unit. The fill light module includes multiple light sources (white light LED, yellow light LED, blue light LED, infrared LED) that can be controlled independently or together, providing comprehensive illumination assistance for the camera in dark warehouse environments while maintaining ease of operation through automated or manual control modes.
2Ease of operation
If the operator relies on direct observation in dark warehouse environments, then no additional equipment is needed, but the operator cannot observe the pallet fork at appropriate viewing angles and must make repetitive adjustments
Solution Approach 1:
The patent introduces a camera as an intermediary device that captures images of the pallet fork and surrounding area, which are then displayed on a monitor in the operator's cabin. This allows the operator to view the fork at appropriate angles without physically adjusting their position or making repetitive adjustments, saving time and improving ease of operation in dark warehouse environments.
3Reliability
If the operator needs to verify merchandise content before operation, then product safety is improved, but operation efficiency decreases due to the need for additional verification instruments
Solution Approach 1:
The patent integrates multiple functions into a single camera system: observation of the pallet fork, illumination in dark environments, and identification of merchandise through optical codes (barcodes, QR codes). This multi-functional system eliminates the need for separate verification instruments, allowing operators to verify merchandise content directly through the camera system, thereby improving both reliability and productivity.
4Measurement precision
If a camera system is used to assist observation, then the operator can see the pallet fork, but the system lacks precise positioning assistance for alignment
Solution Approach 1:
The patent employs a laser positioning system that projects colored laser lines (red, green, blue) onto the pallet fork and surrounding area. These laser lines provide precise positioning references for alignment, working in conjunction with the camera system to enhance measurement precision without significantly increasing device complexity, as the laser module can be integrated into the existing camera housing.
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
The system increases operation efficiency by enabling direct merchandise identification and smooth pallet fork alignment, improving safety and convenience by providing clear images and visual markers in low-light conditions.
Implementation Method 1
the fill light module comprises a plurality of fill light lamps arranged at a surrounding of the camera lens
Implementation Method 2
the camera device further comprises a laser head for projecting an auxiliary positioning laser beam toward a front thereof
Data Source
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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.