Forklift Load Carrier Radar Sensing for Precise Load Positioning
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Solution Overview
Problem
Existing forklift trucks lack efficient means to determine the relative position between the load-bearing element and the load or storage position, leading to imprecise handling during load picking and placement.
Innovation Solution
Equipping the forklift truck with radar sensors on the height-adjustable load-bearing element to measure distances to the load and storage position, determining the relative position, and providing this information to an assistance device for precise handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radar sensors are installed on the load-bearing element to measure distances to the load and storage position, then the relative position determination precision is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems (such as mechanical linkages, optical encoders, or mechanical position sensors) with radar sensors that use electromagnetic waves to measure distances. This substitution achieves high measurement precision for relative position determination while simplifying the overall device structure, as radar sensors are compact and require minimal mechanical integration compared to traditional mechanical measurement systems.
Solution Approach 2:
The radar sensors on the load-bearing element serve multiple functions: they measure distances to both the load during picking operations and to the storage position during placement operations. This multi-functionality allows a single sensor system to provide relative position data for different operational phases, improving measurement precision without requiring separate specialized sensors for each function, thereby managing device complexity effectively.
2Reliability
If multiple radar sensors are provided on the load-bearing element to detect multiple distances, then the reliability of relative position determination is improved, but the device complexity increases
Solution Approach 1:
The patent divides the measurement function into multiple radar sensors positioned at different locations on the load-bearing element, with each sensor detecting distances to specific targets (load or storage position). This segmentation allows the system to obtain multiple independent distance measurements that can be processed to determine relative position, improving reliability through redundancy while keeping each individual sensor simple and manageable.
Solution Approach 2:
The patent introduces a control unit as an intermediary that processes the distance data from multiple radar sensors to calculate the relative position. This intermediary component consolidates the information from multiple sensors, performing the complex calculation centrally rather than requiring complex integration at the sensor level. This approach improves reliability through multi-sensor data fusion while managing device complexity by centralizing the processing function.
3Manufacturing precision
If the radar sensor detects multiple distances to the load and storage position, then the accuracy of load handling is improved, but the measurement time increases
Solution Approach 1:
The patent implements continuous measurement using radar sensors that operate throughout the load handling process without interruption. The radar sensors continuously detect distances to the load and storage position, providing real-time relative position data during the entire operation sequence. This continuous measurement approach ensures high accuracy in load handling while minimizing measurement time, as the system always has current position information available without requiring separate measurement phases or stops.
Solution Approach 2:
The patent performs preliminary distance measurements using the radar sensors before the actual load handling operation begins. By pre-measuring the distances to the load and storage position, the system establishes the relative position in advance, allowing the operator to have accurate position information ready before the lifting or placement operation starts. This preliminary action reduces the time needed during the actual handling operation while maintaining high accuracy.
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 precise and reliable handling of loads by providing real-time relative position data to the operator or assistance system, enhancing safety and accuracy in load lifting and placement operations.
Implementation Method 1
At least one radar sensor is provided on the height-adjustable load-bearing element, which is directed towards a load to be picked up, i.e., in an area in front of the load-bearing element. The radar sensor detects a multitude of distances to the load to be picked up.
Data Source
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AI summary
Industrial truck with a drive unit and a load unit, equipped with a height-adjustable load carrier, wherein at least one radar sensor is provided on the load carrier which is directed towards a load to be picked up and detects a plurality of distances to it, wherein a relative position of load carrier and load to be picked up is determined from the detected distances and made available to an assistance device.