Lead-Follower Forklift Control for Mixed-Automation Logistics
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Solution Overview
Problem
In logistics systems, the mixed operation of autonomously driving and manually controlled industrial trucks poses challenges due to varying work complexity, with complex tasks like order picking remaining inaccessible to automation, necessitating a solution to optimize their joint operation.
Innovation Solution
A logistics system comprising a master industrial truck equipped for autonomous driving and slave trucks of lower automation levels, where the master truck remotely controls the slave trucks via a wireless data connection, ensuring they stay within its monitored area, using sensors and communication units for navigation and collision avoidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If autonomously driving industrial trucks are used for simple tasks, then productivity is improved, but device complexity increases due to expensive autonomous driving hardware
Solution Approach 1:
The system segments the automation function into two parts: the lead truck carries the complex autonomous driving hardware and control systems, while the slave trucks use simpler manual or low-automation systems. This segmentation allows slave trucks to benefit from automation without requiring full autonomous driving capabilities, reducing their hardware complexity while maintaining productivity benefits.
Solution Approach 2:
The lead truck serves multiple functions: it performs its own transportation tasks while simultaneously acting as a mobile control station for the slave trucks. The autonomous control unit on the lead truck can remotely control multiple slave trucks, making the autonomous driving hardware universal across the entire convoy rather than requiring separate systems in each vehicle.
2Adaptability or versatility
If manually controlled industrial trucks are used for complex tasks, then adaptability is improved, but productivity decreases due to lack of automation
Solution Approach 1:
The lead truck acts as an intermediary between the control system and the slave trucks. It receives complex task instructions and translates them into remote control commands for the slave trucks, enabling automated execution of complex tasks like order picking without requiring the slave trucks to have full autonomous capabilities.
3Adaptability or versatility
If mixed operation of autonomous and manual trucks is implemented, then versatility is improved, but safety worsens due to interaction between different automation levels
Solution Approach 1:
The system merges the autonomous lead truck and manual slave trucks into a unified convoy under single control. The autonomous control unit on the lead truck coordinates the movements of both trucks, ensuring they operate as a unified system rather than independent vehicles, which improves safety by eliminating unpredictable interactions between different automation levels.
Solution Approach 2:
The system implements continuous feedback through wireless communication between the lead and slave trucks. The autonomous control unit monitors the position and status of the slave truck and adjusts control commands in real-time, ensuring safe operation. The slave truck's sensors and communication units provide feedback to the lead truck, enabling closed-loop control for enhanced safety.
Data Source
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AI summary
The invention relates to a logistics system 2 comprising a lead industrial truck 4 and at least one follower industrial truck 6, wherein the lead industrial truck 4 is equipped and configured for autonomous driving operation and the follower industrial truck 6 is not equipped and configured for autonomous driving operation. The lead industrial truck 4 includes an environmental monitoring system 8, which defines an environmental monitoring area 10, wherein the lead industrial truck 4 and the at least one follower industrial truck 6 each have a communication unit 14 configured to operate a wireless data connection 16 between the lead industrial truck 4 and the at least one follower industrial truck 6. The lead industrial truck 4 and the follower industrial truck 6 are configured such that the lead industrial truck 4 remotely controls the follower industrial truck 6 via the wireless data connection 16.The lead forklift 4 includes an autonomy control unit 20, which is configured to control the follower forklift 6 along a target path 26 and to determine the position and orientation of the follower forklift 6 for control purposes. The autonomy control unit 20 is configured to remotely control the follower forklift 6 in such a way that it remains within the environmental monitoring area 10 of the lead forklift 4 at all times during its journey.