Autonomous Forklift Load Detection Above the Fork
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Solution Overview
Problem
Existing autonomous forklift trucks lack the ability to reliably detect various types of loads on storage shelving, such as loads with holes or bores, which poses safety risks during automated operations.
Innovation Solution
An autonomous forklift truck equipped with a contactless detection device that emits a light beam to scan a predefined detection zone above the load, combined with a measuring device to determine the fork's height relative to the ground, and a control unit to manage the forklift's operations based on this information, ensuring safe load deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rangefinders or photoelectric cells are used to detect loads on storage shelving, then the detection capability is limited to certain types of loads, but the device complexity is reduced
Solution Approach 1:
The patent replaces traditional mechanical contact-based detection methods with a laser-based optical detection system. The laser beam projects a detection plane that can remotely sense the presence of loads without physical contact, enabling reliable detection of various load types including those with holes or bores that would defeat contact-based sensors.
Solution Approach 2:
The patent introduces a laser beam as an intermediary detection medium that creates a virtual detection plane between the forklift and the storage shelving. This intermediary allows the system to detect loads indirectly through light interaction, providing reliable detection without requiring direct contact or line-of-sight to specific features of the load.
2Reliability
If the detection device is positioned to scan below the load, then the load blocks the detection beam, but the device structure is simpler
Solution Approach 1:
The patent changes the spatial dimension of detection by positioning the laser detection device above the load rather than below it. The laser beam projects downward to create a detection plane that scans the storage shelving area, allowing the beam to pass over the load and detect obstacles in the detection zone without being blocked by the load itself.
3Productivity
If the forklift truck operates autonomously without human intervention, then productivity increases, but safety risks increase
Solution Approach 1:
The patent implements a feedback-based safety system where the laser detection device continuously monitors the detection plane for obstacles. The control unit receives real-time detection signals and can automatically adjust the forklift's operation, such as stopping or altering its path, based on the presence of detected loads or obstacles, thereby maintaining safety during autonomous operation.
Solution Approach 2:
The patent performs preliminary detection of the environment and potential obstacles before the forklift executes its movement or lifting actions. The laser detection system scans and maps the storage shelving area in advance, allowing the control unit to plan safe autonomous operations and avoid collisions or unsafe maneuvers before they occur.
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 reliable detection of any type of load, preventing collisions and ensuring safe, automated load placement without human intervention, enhancing safety and operational efficiency.
Implementation Method 1
a contactless detection device mobile conjointly with the lifting member and configured to emit a light beam directed toward the front of the forklift truck and sweeping at least one predefined plane detection zone
Data Source
AI summary
This autonomous forklift truck (1) comprises: a lifting member (2) comprising a vertically mobile fork (4) provided with at least one arm (4a, 4b) for lifting loads, a drive system (6) for moving the truck (1), and a control unit (14) able to control the operation of the drive system (6) for autonomous guidance of the truck and able to control the vertical movement of the fork (4). The truck further comprises a device (8) for contactless detection of an obstacle mobile conjointly with the lifting member (2). The detection device (8) is able to emit a light beam sweeping at least one predefined plane detection zone to detect the presence or the absence of an obstacle. The detection device (8) is fixed to the lifting member so that the light beam passes above the transported load.