Forklift Cargo Control Using One-Dimensional Laser Sensors
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Solution Overview
Problem
Conventional cargo handling control units for forklifts rely on expensive two-dimensional laser distance meters to accurately position cargo, and the determination of cargo shift requires costly corrections.
Innovation Solution
A cargo handling control unit utilizing a pair of one-dimensional laser distance sensors on both sides of the forklift to determine the picking and placing positions of cargo, allowing for accurate loading without the need for expensive sensors, by controlling the traveling and lift mechanisms based on sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a two-dimensional laser distance meter is used to measure cargo position, then measurement precision is improved, but device cost increases significantly
Solution Approach 1:
The patent divides the measurement task into multiple one-dimensional laser distance sensors positioned at different locations (front, rear, left, right of the cargo). Each sensor measures distance in one dimension, and the controller integrates these multiple one-dimensional measurements to calculate the cargo's position and orientation, replacing a single expensive two-dimensional sensor array.
Solution Approach 2:
The patent combines multiple one-dimensional laser distance measurements from different positions to achieve two-dimensional or three-dimensional positioning capability. The controller integrates distance data from multiple sensors to calculate cargo position, orientation, and dimensions, merging simple measurements into complex spatial information.
2Measurement precision
If a two-dimensional laser distance meter is used to determine loading position shifts, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the positioning function across multiple simple one-dimensional sensors rather than using a single complex two-dimensional sensor. Each sensor is positioned at a specific location and measures distance in its respective direction, simplifying the individual sensor requirements while achieving comprehensive coverage through their combination.
Solution Approach 2:
The one-dimensional laser distance sensors serve multiple functions: measuring cargo distance, determining cargo position, detecting loading shifts, and calculating cargo dimensions. The same simple sensor type is used for all these purposes by varying its position and the processing algorithm, reducing the need for specialized expensive sensors.
3Ease of manufacture
If multiple one-dimensional laser distance sensors are used instead of a two-dimensional sensor, then device cost decreases, but the number of sensors increases
Solution Approach 1:
The patent uses multiple inexpensive one-dimensional laser distance sensors instead of a single expensive two-dimensional sensor system. The individual one-dimensional sensors are cheaper components that can be mass-produced, and their lower individual cost compensates for using multiple units, making the overall system more cost-effective.
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
Enables accurate and cost-effective loading and unloading of cargo at predetermined positions, reducing the reliance on expensive two-dimensional laser systems and improving operational efficiency.
Implementation Method 1
Each of the right and left one-dimensional laser distance sensors is configured to emit a one-dimensional laser beam ahead of the forklift and receive the laser beam reflected from an object
Implementation Method 2
receive the laser beam reflected from an object that is located in front of the forklift
Data Source
AI summary
A cargo handling control unit of a forklift includes a traveling device including a traveling drive unit, forks loading cargos, and a cargo handling device having a lift cylinder. The cargo handling control unit includes at least a pair of one-dimensional laser distance sensors, each of which is configured to emit a one-dimensional laser beam and receives the laser beam reflected from an object, thereby detecting a distance between the object and the one-dimensional laser distance sensor, a picking start position determination unit determining a picking start position of the forks for the cargos, and a picking control unit being configured to control the traveling drive unit and the lift cylinder so as to load the cargos on the forks.