Laser Scanner Positioning for Industrial Truck Navigation
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Solution Overview
Problem
Existing industrial trucks, such as order pickers and high-rack stackers, face challenges in navigating rack storage facilities due to unclear orientation and repetitive structures, leading to driver confusion and inefficiencies in locating pallets, especially with suboptimal RFID tag reception conditions and limited camera visibility.
Innovation Solution
Equipping industrial trucks with transversely oriented laser scanners to detect barcode labels on shelves, allowing for accurate position determination and automatic identification of pallet locations, and using a control device to calculate and display the route to the destination, enabling precise navigation and lifting adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If extensive and complex signage is installed within the rack warehouse to guide drivers, then driver orientation and location finding are improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical signage system with an automated sensor-based system. Environment sensors (cameras, laser scanners) mounted on the industrial truck automatically detect markings on shelves and determine location, eliminating the need for extensive physical signage while improving orientation capability
Solution Approach 2:
The industrial truck equips itself with environment sensors and control devices that enable autonomous location determination. The truck's own sensor system processes markings detected in the environment to automatically identify shelf locations, making the truck self-sufficient for navigation without external signage assistance
2Measurement precision
If RFID tags are attached to loads for identification, then load identification is improved, but reception conditions become suboptimal when tags are at different assembly positions
Solution Approach 1:
The patent introduces markings (such as barcode labels or optical markers) on shelves as an intermediary reference system. Instead of relying solely on RFID tags on loads, the environment sensors detect these fixed shelf markings to determine location, providing reliable identification regardless of load position or RFID tag placement
3Illumination intensity
If camera sensors are used for environmental detection, then forward visibility is improved when loads are picked up, but location determination capability is insufficient
Solution Approach 1:
The patent makes the environment sensor system multi-functional by equipping it with both camera sensors for load identification and laser scanners specifically for location determination. The same sensor mounting system on the truck handles both functions, improving overall system capability without adding separate dedicated systems
Solution Approach 2:
The patent adds the dimension of lateral scanning capability through laser scanners that detect markings on shelves from the side. This complements the forward-facing camera system, enabling the truck to determine its horizontal position within the rack warehouse by scanning markings on vertical shelf elements
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 solution enables easy and safe navigation within rack storage facilities by providing accurate location detection and automatic identification of pallets, reducing driver confusion and manual scanning, while allowing the truck to operate efficiently without turning, with improved accuracy and reduced signage needs.
Implementation Method 1
One embodiment shows that the distance sensors work with a light beam that illuminates a mirror arranged at the top of a shelf.
Data Source
Figure 1
AI summary
The conveyor i.e. order picker (4), has a proximity sensor i.e. laser scanner (10), for detecting barcode-labels (9) fixed in a high-bay rack at a storage rack (1). The sensor is oriented along a detecting direction of the sensor to sides of the conveyor, corresponding to a vehicle longitudinal axis (6). The sensor scans perpendicularly and opposite to the base oriented barcode-labels. A control device detects an actual position of the conveyor between the barcode-labels over a reclined distance. An independent claim is also included for a method for target-setting of a storage system.