Forklift Drop Camera Assembly for Under-Fork Obstacle Detection
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Solution Overview
Problem
Autonomous or semi-autonomous forklift trucks face challenges in safely placing pallets due to obstacles in the target location, risking damage to the truck, pallet, or items, as existing systems lack effective obstacle detection and alignment mechanisms.
Innovation Solution
A drop camera assembly is integrated into the forklift, featuring a carriage camera for pallet alignment and a drop camera that retracts and extends to detect obstacles below the forks, using gas springs for passive actuation to avoid interference with navigation lidars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drop camera is extended to view obstacles below the forks, then obstacle detection capability is improved, but the camera is at risk of damage during routine use
Solution Approach 1:
The drop camera is designed to be movable between an extended position (for obstacle detection) and a retracted position (for protection). The camera extends below the forks when needed and retracts when the carriage is lowered, dynamically adapting its position to balance detection capability with damage protection.
Solution Approach 2:
The system automatically retracts the drop camera when the carriage is lowered to ground level, before any potential damage can occur. This preliminary protective action prevents the camera from being exposed to harmful conditions during routine operation.
2Area of stationary object
If the drop camera remains stationary with the carriage camera, then the assembly is compact, but the view is obstructed by pallets on the forks
Solution Approach 1:
The drop camera is positioned offset from the carriage camera and can extend downward independently. This dynamic positioning allows the camera to move from a nested compact position to an extended viewing position below the pallet, eliminating view obstruction while maintaining compactness when not in use.
Solution Approach 2:
Instead of placing the drop camera in the same horizontal plane as the carriage camera, it is positioned in a different spatial dimension (offset and extendable vertically). This dimensional separation allows both cameras to coexist compactly while providing unobstructed viewing angles.
3Reliability
If the drop camera is extended continuously, then obstacle detection is always available, but the camera interferes with navigation lidars during normal operation
Solution Approach 1:
The drop camera extends and retracts dynamically based on operational needs. It extends when obstacle detection is required and retracts when the carriage is lowered for normal operation, allowing navigation lidars to function without interference. This dynamic adaptation resolves the conflict between continuous detection and lidar compatibility.
4Ease of manufacture
If a passive actuation system is used for the drop camera, then the system is cost-effective and simple, but the camera position control may be less precise
Solution Approach 1:
The drop camera uses a passive actuation system that automatically extends and retracts based on the carriage position and operational conditions, without requiring additional active control mechanisms. The system self-regulates its position based on mechanical linkages and sensors, providing cost-effective and simple control while maintaining sufficient precision for the application.
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 drop camera assembly provides reliable and cost-effective obstacle detection, ensuring precise pallet placement by accurately determining the location and orientation of objects, while protecting the camera from damage during normal operation.
Implementation Method 1
using gas springs for passive actuation
Data Source
AI summary
A forklift includes a carriage that has one or more forks. A drop camera assembly is coupled to the forklift. The drop camera assembly includes a drop camera. The drop camera is configured to move from a retracted position to an extended position. The drop camera is located proximal to the forks when in the retracted position. The drop camera is positioned away from the carriage when in the extended position so as to image one or more obstacles under the forks of the carriage. The drop camera assembly further includes a carriage camera that is secured to the carriage. The carriage camera is configured to show alignment of the forks relative to a pallet or other object to be handled by the forklift.