Forklift Speed Regulation via Operator Position Sensing
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Solution Overview
Problem
Existing control methods for industrial trucks during order picking are limited by fixed driving speed and inability to adjust the truck's distance from the operator, leading to uncomfortable and jerky movements, especially in large warehouses where operators must cover long distances and handle heavy loads.
Innovation Solution
A method that uses surroundings sensors to detect the operator's position and movement speed, allowing the industrial truck's speed to be regulated accordingly, enabling the operator to set their preferred position and movement speed, and adapt to environmental conditions, ensuring smooth and ergonomic operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the driving speed of the industrial truck is set to a fixed value, then the control system is simple, but the operator cannot adjust the speed to match their walking pace, leading to jerky movements and operator fatigue
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed driving speed to a variable speed system that adapts to the operator's walking pace. The control unit continuously adjusts the truck's driving speed based on real-time detection of the operator's position and movement, enabling smooth acceleration and deceleration that matches natural human walking patterns, thereby eliminating jerky movements and improving operator comfort
Solution Approach 2:
The patent implements feedback by using surroundings sensors to continuously monitor the operator's position relative to the truck and feed this information back to the control unit. The control unit processes this feedback and adjusts the driving speed accordingly, creating a closed-loop control system that automatically adapts to the operator's movements without requiring manual input, thus maintaining simplicity while improving comfort
2Ease of operation
If the operator must make further adjustments to influence the driving speed, then the speed can be adapted to operator needs, but the operator's full attention must be directed to this process while the truck is moving
Solution Approach 1:
The patent applies self-service by enabling the industrial truck to automatically adjust its own driving speed based on the operator's position and movement detected by surroundings sensors. The control unit autonomously manages speed regulation without requiring the operator to intervene, allowing the operator to walk naturally while the truck adapts to their pace, thus maintaining safety while achieving speed adaptability
Solution Approach 2:
The patent uses feedback to continuously monitor the operator's position and automatically regulate the driving speed. The control unit receives real-time data from sensors about the operator's location and movements, processes this information, and automatically adjusts the truck's speed to match the operator's walking pace, eliminating the need for operator intervention and ensuring safety
3Ease of operation
If the operator cannot adjust the vehicle's distance during movement, then the control system is simple, but the operator cannot maintain a comfortable or safe distance from the truck
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed distance relationship to a dynamic distance adjustment system. The surroundings sensors continuously detect the operator's position, and the control unit automatically adjusts the truck's position and speed to maintain an optimal distance from the operator, enabling comfortable and safe operation while adapting to the operator's natural walking patterns
Solution Approach 2:
The patent implements feedback by using sensors to continuously monitor the operator's position relative to the truck and feeding this information back to the control unit. The control unit processes this feedback and automatically adjusts the truck's distance from the operator, creating a dynamic safety zone that adapts to the operator's movements without requiring manual intervention
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 approach allows for a human-centered control system where the operator determines the working speed, reducing operator fatigue and improving ergonomics by providing a stable and even follow-up movement, avoiding jerky or oscillating truck behavior and ensuring safe lateral distance maintenance.
Implementation Method 1
Optical environment sensors are known for such industrial trucks, with which the environment of the industrial truck is detected. These can be, for example, two-dimensional laser scanners (2-D laser scanners) or three-dimensional laser scanners (3-D laser scanners), cameras, monocular cameras as well as optical sensors that record distances
Implementation Method 2
Ultrasonic sensors are also possible
Data Source
Figure 1
AI summary
In a method for controlling a forklift truck (1) during order picking, wherein the forklift truck (1) has at least one environmental sensor (8) for detecting the relative position of an operator (9) in the vicinity of the forklift truck (1), the forklift truck (1) is moved by a controller in response to a change in the position of the operator (9), wherein the position of the operator (9) is freely selectable and the movement speed of the operator (9) is determined by the controller, as well as the driving speed of the forklift truck (1) being regulated by the controller according to the movement speed of the operator (9).