Autonomous Forklift Load Detection Using a Swept Light Plane
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Solution Overview
Problem
Existing autonomous lift trucks face challenges in reliably detecting loads, especially those with holes or bores, using conventional mechanical sensors, necessitating modifications to storage shelving designs and risking human intervention for verification.
Innovation Solution
Equipping the lift truck with a contactless load-detection device that emits a beam of light to sweep a predefined planar detection zone above the fork blades, allowing reliable detection of loads regardless of shape or size, and integrating a control unit to command the drive system based on detection information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical sensors are used on the fork, then load detection is possible, but detection reliability deteriorates for loads with holes or bores
Solution Approach 1:
The patent replaces mechanical contact-based sensors with a laser-based optical detection system. The laser beam projects a plane onto the load surface, and optical sensors detect the reflected light pattern to determine load presence and position, eliminating the need for mechanical contact that fails with hollow or irregularly shaped loads.
Solution Approach 2:
The invention changes the detection parameter from mechanical contact force to optical reflection characteristics. By measuring the reflection pattern of the laser plane, the system can detect loads regardless of their internal structure (solid, hollow, porous), thereby improving detection reliability across different load types.
2Reliability
If mechanical sensors are installed at the back of the fork, then load detection is achieved, but the fork cannot reach positions to detect loads set back on shelving
Solution Approach 1:
The patent transitions from point-based mechanical sensor detection to plane-based optical detection. The laser projects a two-dimensional plane onto the load, enabling detection of loads at various depths and positions on shelving, thereby increasing adaptability to different storage configurations without requiring fork repositioning.
3Ease of operation
If point measurement telemeters are used, then remote load detection is possible, but detection completeness deteriorates for loads with holes or bores
Solution Approach 1:
The system upgrades from one-dimensional point measurement to two-dimensional plane projection using a laser. This allows the optical sensors to capture reflection patterns across the entire load surface, providing complete detection information for complex-shaped loads including those with holes, bores, or irregular geometries.
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 safe and reliable detection of loads without modifying shelving designs, enhancing safety and reliability by ensuring accurate load positioning and transport without human intervention.
Implementation Method 1
The detection device is able to emit a beam of light that sweeps at least a predefined planar detection zone situated above at least one of the blades of the fork so as to detect the presence or absence of a load
Data Source
AI summary
This autonomous lift truck (1) comprises: a vertically mobile fork (4) equipped with at least two blades (4a, 4b) for lifting loads, a drive system (7) for moving the truck, and a control unit (9) able to command the operation of the drive system for autonomously guiding the truck and able to command the vertical movement of the fork (4). The truck further comprises a contactless load-detection device (10) able to move together with the fork and positioned above the blades (4a, 4b) of the fork. The contactless detection device (10) is able to emit a beam of light that sweeps at least a predefined planar detection zone situated above the blades of the fork so as to detect the presence of a load that is to be lifted.