Forklift Laser Sensor 3D Pallet Position Detection
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Solution Overview
Problem
Conventional forklift technologies are unable to accurately detect lateral displacement and rotational displacement of pallets during load-lifting operations, limiting the precision of load positioning and increasing the risk of interference between the fork and pallet.
Innovation Solution
A forklift equipped with a laser sensor mounted on the fork that scans laser light in a horizontal direction while moving vertically, allowing the generation of a three-dimensional range image to detect positional displacements in the lateral direction and rotation, enabling accurate identification of pallet position, orientation, and width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a reflective optical sensor is used to detect pallet position, then heightwise displacement can be detected, but lateral displacement and rotational displacement cannot be detected
Solution Approach 1:
The patent transitions from one-dimensional height detection to three-dimensional spatial detection by mounting a laser sensor on the fork that scans in multiple directions. The laser sensor emits laser beams in the vertical direction and scans in the horizontal direction, capturing distance information in three-dimensional space to detect lateral and rotational displacements of the pallet.
2Measurement precision
If a laser sensor is mounted on the fork to enable three-dimensional scanning, then lateral and rotational displacement can be detected, but the device complexity increases
Solution Approach 1:
The laser sensor mounted on the fork serves multiple functions: it detects vertical height, lateral displacement, and rotational displacement of the pallet simultaneously. By integrating the sensor into the fork structure, the system achieves comprehensive three-dimensional detection capability without requiring separate sensing systems for each measurement type.
3Device complexity
If conventional optical sensors are used, then the device configuration remains simple, but detection of lateral and rotational displacement is not possible
Solution Approach 1:
The patent replaces conventional reflective optical sensors with a laser sensor system that uses laser beam scanning. This substitution enables three-dimensional measurement capability by utilizing the laser's coherent light properties and time-of-flight measurement, replacing the limited two-dimensional detection of conventional sensors with comprehensive spatial detection.
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
This configuration enhances the accuracy of pallet positioning, preventing interference and ensuring smooth load-lifting operations by detecting lateral and rotational displacements, thereby improving the overall efficiency and safety of the forklift's load-lifting process.
Implementation Method 1
measure a distance from the laser sensor to a surrounding object based on reflected light of the scanned laser light
Implementation Method 2
measure a distance from the laser sensor to a surrounding object based on reflected light of the scanned laser light
Data Source
AI summary
A forklift includes: a fork 22, a moving mechanism configured to move the fork in a first direction; a laser sensor 20 mounted on the fork, configured to scan laser light in a second direction intersecting the first direction, and measure a distance from the laser sensor to a surrounding object based on reflection of the scanned laser light; and a processor configured to generate a three-dimensional range image within an emission range to which the laser light is emitted based on distance data acquired when the laser sensor scans the laser light in the second direction while the moving mechanism moves the fork in the first direction.