Forklift Thermal Mapping for Warehouse Energy Control
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Solution Overview
Problem
Existing warehouse management systems lack efficient energy management and temperature control for forklift trucks, leading to suboptimal energy use and environmental monitoring.
Innovation Solution
A data processing device for forklift trucks that utilizes thermal imaging and position data to create a dynamic 3D temperature map, enabling precise temperature monitoring and control, along with object recognition and energy management integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thermal imaging sensors and processing systems are integrated into forklift trucks to create temperature maps, then temperature monitoring precision and energy management capability are improved, but device complexity increases
Solution Approach 1:
The system divides the warehouse into a grid of spatial points and creates temperature maps by segmenting thermal data from multiple forklift positions. Each forklift captures thermal images of specific zones, which are then segmented and merged to form complete temperature maps of different warehouse areas.
Solution Approach 2:
The forklift truck serves multiple functions: it performs material handling operations while simultaneously acting as a mobile thermal imaging platform for temperature monitoring. The integrated system enables the forklift to collect thermal data, process it into temperature maps, and provide this information to the warehouse management system.
2Area of stationary object
If multiple forklift trucks are equipped with thermal imaging sensors and data processing systems, then comprehensive temperature monitoring coverage is improved, but energy consumption increases
Solution Approach 1:
Temperature maps are created periodically as forklifts naturally traverse different warehouse zones during their material handling operations. The system captures thermal data at regular intervals based on forklift position and movement, rather than requiring continuous active monitoring, thereby reducing energy consumption while maintaining comprehensive coverage.
3Productivity
If real-time temperature data from multiple forklifts is collected and processed to create dynamic temperature maps, then energy management effectiveness is improved, but data processing complexity increases
Solution Approach 1:
The system implements feedback mechanisms where temperature maps generated from forklift data are fed back to the warehouse management system. This feedback enables automatic adjustment of cooling system operations, optimization of forklift routing to prioritize high-temperature zones, and real-time energy management decisions based on current thermal conditions.
Solution Approach 2:
The system creates digital copies of thermal data in the form of temperature maps that represent the physical warehouse state. These digital temperature maps are processed and analyzed to generate control signals, allowing the system to manage energy consumption based on virtual representations rather than directly manipulating physical systems.
4Measurement precision
If thermal imaging cameras and processing systems are integrated into forklift trucks, then temperature monitoring capability is improved, but manufacturing cost increases
Solution Approach 1:
The forklift truck is designed as a multi-functional platform that combines material handling capabilities with thermal imaging and temperature monitoring functions. By making the forklift universal, the system avoids the need for separate dedicated temperature monitoring equipment, thereby reducing overall manufacturing costs while maintaining advanced temperature monitoring capabilities.
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
Enhances energy efficiency by optimizing temperature control and reducing energy consumption, while providing real-time monitoring and predictive maintenance for warehouse environments.
Implementation Method 1
a thermal imaging device, in particular a thermal imaging camera, wherein the thermal imaging device is configured to combine the large number of sensor data with the large number of thermal image data
Data Source
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AI summary
The invention relates to a data processing device or control unit (123) for operating a forklift truck (120a) for transporting a plurality of goods (140) in a warehouse. The data processing device (123) comprises an interface (123b) configured to receive a plurality of sensor data from the forklift truck (120a) during its movement in the warehouse, wherein the plurality of sensor data includes a plurality of thermal imaging data of the forklift truck's (120a) surroundings. Furthermore, the data processing device (123) comprises a processor (123a) configured to create or update a temperature map of the warehouse based on the plurality of thermal imaging data, wherein the temperature map indicates a respective temperature value for a plurality of points in the warehouse. The data processing device or control unit (123)The control unit (123) can be part of the industrial truck (120a) or a stand-alone server.