Forklift Drone Camera for Blind Spot Elimination
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Solution Overview
Problem
Conventional forklift operation assist systems are cumbersome due to the need for multiple ID tags and cameras per conveyor, and existing camera systems on forklifts are prone to damage and image blurring from vibrations.
Innovation Solution
A forklift operation assist system featuring a small unmanned aerial vehicle (SUAV) with an image capture device that autonomously flies above the forklift, providing real-time images to the operator via a display device, eliminating the need for extensive equipment setups and reducing camera vulnerability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple ID tags and monitoring cameras are provided for each conveyor, then the forklift operation assist system can capture images of load handling areas, but the system becomes large in size and requires extensive setup
Solution Approach 1:
The patent extracts the image capture function from the fixed conveyor-mounted cameras and relocates it to a mobile platform (drone or forklift-mounted camera). This allows a single mobile camera to replace multiple fixed cameras across different conveyors, reducing system complexity while maintaining the ability to capture load handling images wherever needed
Solution Approach 2:
The mobile camera platform serves multiple conveyors and locations universally, rather than requiring dedicated cameras for each conveyor. The camera system can move between different work areas to capture images at various load handling points, making the system more versatile and reducing the total number of cameras needed
2Reliability
If a camera is mounted in the front tip end of the forklift fork, then blind spots are eliminated, but the camera is susceptible to contamination and damage from impact and vibration
Solution Approach 1:
The patent extracts the camera from the harsh environment at the forklift fork tip and relocates it to a protected location on the forklift body or to a mobile drone platform. This separation protects the camera from contamination, impact, and vibration while maintaining the ability to capture forward view images
Solution Approach 2:
The patent introduces an intermediary platform (drone or protected mounting structure) between the forklift and the camera. This intermediary protects the camera from direct exposure to harmful factors while still enabling the camera to capture the necessary forward view imagery
3Ease of operation
If a camera system is mounted on the forklift, then real-time images can be provided to the operator, but energy is consumed continuously even when not needed
Solution Approach 1:
The patent implements periodic or on-demand activation of the camera and SUAV based on forklift operational state. The system activates the camera only when the forklift is performing load handling operations (when forks are raised or load is present), and deactivates it during idle periods, thereby reducing energy consumption while maintaining real-time imaging capability when needed
Data Source
AI summary
A forklift operation assist system includes a forklift truck having a load-handling device with a lifting portion, a small unmanned aerial vehicle that is mountable on the forklift truck and has an image capture device, and a display device that presents images captured by the image capture device. The forklift truck includes a vehicle controller that is electrically connected to the display device. The small unmanned aerial vehicle includes an aircraft controller that communicates with the vehicle controller. The small unmanned aerial vehicle takes off the forklift truck when a lifting operation of the lifting portion is detected. The display device presents the images captured by the image capture device while the aerial vehicle is flying.