Autonomous Forklift Obstacle Sensing for Safe Load Set-Down
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Solution Overview
Problem
In environments like factories or warehouses, autonomous lift trucks require human intervention to ensure safe operation, particularly during load setting-down, due to the risk of pedestrians being crushed between the load and storage structures, despite having contactless obstacle detection systems that need deactivation near these structures.
Innovation Solution
An autonomous lift truck equipped with two contactless detection devices, one fixed below and one above the lifting member, controls the vehicle's movement and lifting operations to avoid obstacles, ensuring safe load setting-down by activating and deactivating these devices at specific stages of the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contactless detection device is deactivated during load setting-down to avoid false detection of storage structures, then the lift truck can reach the setting-down position, but the risk of pedestrian injury increases
Solution Approach 1:
The detection system is divided into two separate contactless detection devices: a first device for general obstacle detection and a second device specifically for pedestrian detection during load setting-down operations. This segmentation allows each device to be optimized for its specific function and activated/deactivated independently based on operational context
Solution Approach 2:
The second contactless detection device is activated before the load setting-down operation begins and remains active during the critical phase when the load is positioned near storage structures. This preliminary activation ensures pedestrian protection is in place before the hazard occurs, allowing the system to detect and respond to pedestrians in the detection zone
2Object-affected harmful factors
If the contactless detection device remains active during load setting-down to detect obstacles, then pedestrian safety is improved, but the storage structure is falsely detected as an obstacle preventing the setting-down operation
Solution Approach 1:
The detection system is divided into two separate contactless detection devices: a first device for general obstacle detection and a second device specifically for pedestrian detection during load setting-down operations. This segmentation allows each device to be optimized for its specific function and activated/deactivated independently based on operational context
Solution Approach 2:
The activation state of the second contactless detection device is dynamically changed based on the operational phase. The control unit activates the second device before load setting-down and deactivates it after the operation is complete, allowing the system to adapt its detection behavior to the current operational context and avoid false detections of storage structures
3Reliability
If human intervention is required to check operations and ensure safety, then operational correctness can be verified, but productivity and automation level are reduced
Solution Approach 1:
The autonomous lift truck performs self-monitoring and self-protection functions through the dual contactless detection device system. The control unit automatically activates/deactivates the second detection device, monitors for pedestrians, and controls the lifting member to prevent injuries, eliminating the need for human operators to continuously monitor these specific safety functions
Solution Approach 2:
The second contactless detection device provides continuous feedback about the presence of pedestrians in the detection zone during load setting-down operations. The control unit receives this information and automatically adjusts the operation of the lifting member and drive system to prevent pedestrian injury, creating a closed-loop safety system that operates autonomously
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 solution enhances safety by preventing pedestrians from being crushed between the load and structures during load setting-down, ensuring the truck approaches safely without human intervention.
Implementation Method 1
a first contactless detection device, which is fixed with respect to the truck and can emit a first light beam having a main emission direction that is oriented horizontally towards the front of the lift truck in order to detect an obstacle situated in front of said truck
Data Source
AI summary
This autonomous lift truck (1) comprises: a lifting member (2) that can move at least vertically, a drive system (6), a first contactless detection device (9), which is fixed with respect to the truck and makes it possible to detect an obstacle situated in front of the truck, and a control unit (8), which can control the truck on the basis of the information from the first detection device, and can control the movement of the lifting member (2). The truck further comprises a second contactless detection device (11), which is fixed with respect to the truck (1), arranged above the first detection device (9) and can detect an obstacle situated in front of the truck (1). The control unit (8) can control the truck (1) on the basis of the information from the second contactless detection device (11).