Unmanned Forklift Rack Calibration Using an Adjustment Pallet

Solution Overview

Problem

The introduction of an unmanned forklift into a new facility is hindered by the need for time-consuming and costly test traveling to correct initial setting information, such as moving routes and palette placement coordinates, due to position shifts in rack structures caused by assembly and installation inaccuracies.

Innovation Solution

An initial setting method for unmanned forklifts that involves placing a palette for adjustment on a rack structure, acquiring relative position information using a position information acquisition part, and calculating the shift amount of the palette with respect to the palette placing part, thereby correcting the operation program without extensive testing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If test traveling is performed to correct initial setting information, then position accuracy of palette placement is improved, but time and cost for introduction increase

Engineering Contradiction:

Improveposition accuracyVSAvoidintroduction time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-installing position detection markers on the rack structure before the unmanned forklift arrives. This allows the forklift to immediately acquire accurate position information upon introduction, eliminating the need for time-consuming test traveling to detect and correct position deviations. The markers are placed in advance at known coordinates, enabling direct calculation of the forklift's position relative to the rack.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical test traveling process with an optical/electromagnetic detection system. Instead of physically moving the forklift to multiple test positions and manually measuring deviations, the system uses markers detectable by sensors (such as cameras or optical detectors) to automatically determine position accuracy. This substitution dramatically reduces the time and effort required for initial setup.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If test traveling is performed to correct initial setting information, then position accuracy of palette placement is improved, but cost for introduction increases

Engineering Contradiction:

Improveposition accuracyVSAvoidintroduction cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-installing position detection markers on the rack structure before the unmanned forklift arrives. This allows the forklift to immediately acquire accurate position information upon introduction, eliminating the need for time-consuming test traveling to detect and correct position deviations. The markers are placed in advance at known coordinates, enabling direct calculation of the forklift's position relative to the rack.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical test traveling process with an optical/electromagnetic detection system. Instead of physically moving the forklift to multiple test positions and manually measuring deviations, the system uses markers detectable by sensors (such as cameras or optical detectors) to automatically determine position accuracy. This substitution dramatically reduces the time and effort required for initial setup.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If manual measurement of position shift amount is performed, then position accuracy is improved, but operation complexity increases

Engineering Contradiction:

Improveposition accuracyVSAvoidoperation complexity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent applies self-service by enabling the unmanned forklift to automatically detect its own position relative to the rack structure using pre-installed markers. The forklift's detection system automatically acquires marker positions, calculates position deviations, and determines correction amounts without requiring manual measurement or external intervention. This self-determination process maintains high position accuracy while significantly simplifying the operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements feedback by using the detected position information to automatically adjust the forklift's operation program. The system measures the actual position of the forklift relative to the rack markers, calculates the deviation from the expected position, and feeds this information back to correct the operation program. This closed-loop feedback mechanism ensures high position accuracy while automating the correction process.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12209004B2Initial setting method of unmanned forklift, palette for adjustment, and adjustment system of unmanned forklift

Publication Date: 2025.01.28 MITSUBISHI LOGISNEXT CO LTD

AI summary

An initial setting method of an unmanned forklift is an initial setting method when the unmanned forklift is introduced in a facility including a rack structure, which includes placing a palette for adjustment on a palette placing part of the rack structure using the unmanned forklift on the basis of a preset operation program, acquiring relative position information between the palette for adjustment and the rack structure using a position information acquisition part included in the palette for adjustment, and calculating the shift amount of the palette for adjustment placed on the rack structure with respect to the palette placing part on the basis of the relative position information.