Integrated Forklift Radar-Camera Sensor Structure for Cable Routing

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Solution Overview

Problem

Intelligent forklifts face challenges in cable routing due to the significant distance between laser radars and cameras, which complicates installation and increases the risk of collisions during material handling.

Innovation Solution

A sensor device integrating radars and cameras with an inclined centerline and downward tilt, along with a support structure and leveling mechanism, facilitates easier cable routing and enhances obstacle detection capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If laser radar and camera are mounted at different locations (top and side wall), then sensing coverage is improved, but cable routing complexity increases

Engineering Contradiction:
Improvesensing coverageVSAvoidcable routing complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the laser radar and camera into a single integrated sensor device mounted at the top of the forklift. The support structure holds both sensors together, allowing their cables to be routed through a single location rather than requiring separate cable paths from different mounting positions. This combining approach maintains the sensing coverage benefits while eliminating the cable routing complexity that would result from distributed sensor placement.

Inventive Principle:
Principle #5Merging (Combining)

2Device complexity

If laser radar and camera are mounted close together, then cable routing is simplified, but sensing coverage and field of view may be limited

Engineering Contradiction:
Improvecable routing simplicityVSAvoidsensing coverage
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent utilizes vertical space by mounting the integrated sensor device at the top of the forklift body, leveraging the height dimension. The support structure extends vertically with the laser radar positioned at a higher elevation than the camera, allowing both sensors to achieve optimal field of view and sensing coverage while remaining integrated. This vertical arrangement provides wide-angle coverage without requiring horizontal separation that would complicate cable routing.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If radar centerline is vertical, then installation is simple, but obstacle detection coverage is reduced

Engineering Contradiction:
Improveinstallation simplicityVSAvoidobstacle detection coverage
Core Design Contradiction:
Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent employs asymmetric mounting of the laser radar with its centerline inclined relative to the vertical direction. The support structure is designed to accommodate this inclined orientation, positioning the radar at an angle that optimizes obstacle detection coverage for forklift operations. This asymmetric configuration enhances sensing capability while the integrated support structure maintains installation simplicity by providing pre-configured mounting angles.

Inventive Principle:
Principle #4Asymmetry

Data Source

PatentUS20250270078A1Sensor device, forklift, and control method for sensor device
Publication Date: 2025.08.28 WUHU LINGDONG ACCELERATION ROBOTICS TECHNOLOGY CO LTD
  • US20250270078A1 patent drawing
  • US20250270078A1 patent drawing
  • US20250270078A1 patent drawing

AI summary

The present application relates to a sensor device, a forklift, and a control method for the sensor device. The sensor device comprises: a support structure comprising a support plate, pillars, and a fixing member, one end of each pillar being connected to the support plate and the other end being connected to the fixing member; a first radar disposed on the support plate and located between the support plate and the fixing member; and cameras disposed on the support plate and located between the support plate and the fixing member. The sensor device in this application integrates radars and cameras, facilitating cable routing for both radars and cameras, thereby improving production efficiency.