Forklift Load Positioning Using Multi-Level Landmark Segmentation
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Solution Overview
Problem
Existing forklift truck systems face challenges in precise load positioning due to sensitivity to camera placement and shocks, which can result in damage to loads or load racks during handling, especially in automatic pallet handling scenarios.
Innovation Solution
Implementing a global positioning system with landmarks at measured positions, allowing the forklift truck to determine a reference position using a first landmark and then adjust for a second landmark at a higher level, enabling precise load positioning without relying solely on camera precision, and compensating for mismatches and deviations between the truck and load rack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single landmark and camera are used for positioning, then the system is simple, but positioning precision deteriorates due to camera placement sensitivity and shock effects
Solution Approach 1:
The positioning system is segmented into multiple independent landmarks (at least two landmarks at different heights) rather than relying on a single landmark. This segmentation allows the system to distribute positioning measurements across multiple reference points, reducing sensitivity to individual camera placement errors and shock effects on any single landmark-camera relationship.
Solution Approach 2:
The system transitions from two-dimensional positioning (single plane landmark) to three-dimensional positioning by introducing landmarks at different heights (vertical dimension). This dimensional expansion provides additional geometric constraints for triangulation and perspective calculation, enabling more robust position determination that compensates for camera placement variations and shock-induced displacements.
2Measurement precision
If high positioning precision is required for the camera, then load positioning accuracy improves, but the system becomes sensitive to shocks and camera displacement
Solution Approach 1:
The system employs feedback mechanisms by continuously monitoring the positions of multiple landmarks and recalculating the forklift's position based on updated landmark images. This feedback loop allows the system to detect and compensate for camera displacement caused by shocks, maintaining positioning accuracy without requiring the camera to remain perfectly stationary.
Solution Approach 2:
The system performs preliminary positioning calculations using multiple landmarks before critical operations such as load deposition or pickup. By establishing a robust position estimate in advance using redundant landmark measurements, the system creates a safety margin that compensates for potential camera displacement during subsequent shock events.
3Ease of manufacture
If one landmark is used for positioning, then the system is simple to implement, but positioning accuracy deteriorates under shock and misalignment conditions
Solution Approach 1:
The system merges information from multiple landmarks (at least two landmarks at different heights) into a unified position estimate. By combining measurements from multiple reference points, the system achieves higher measurement accuracy while maintaining reasonable implementation complexity, as the additional landmarks can be integrated through established computer vision and triangulation algorithms.
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 method ensures accurate load positioning across multiple levels, reducing the risk of damage by using a combination of global positioning and optical detection means to correct the load carrier's position, even in the presence of shocks or misalignment, thus enhancing safety and efficiency in warehouse operations.
Implementation Method 1
an first image is captured of the first landmark by optical detection means movable with a load carrier
Data Source
AI summary
The present disclosure relates to a method performed in a forklift truck, for determining a load position in a load rack. The forklift truck includes optical detection means movable with a load carrier. The method includes the steps of determining a reference position related to the optical detection means of a first land mark located on a first height of the load rack based on the position of the first landmark in a first image captured by the optical detection means; determining a second position related to the optical detection means of a second land mark located on a second height of the load rack based on the position of the second landmark in a second image captured by the optical detection means at a predetermined height; and determining a load position on the second height based on a comparison between the reference position and the second position.