Load Handling Module With Multi-Camera Fork Alignment
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Solution Overview
Problem
Material handling vehicles lack efficient autonomous systems for accurately picking up and dropping off loads in various locations, including racks and floors, due to limitations in sensing and positioning technologies.
Innovation Solution
A load handling module equipped with multiple cameras and sensors that provide a comprehensive field of view and object detection capabilities, allowing the vehicle to autonomously control fork movement for precise engagement and disengagement of loads, and communicate with a controller for navigation and load management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensing systems are used in material handling vehicles, then the vehicle structure remains simple, but the vehicle cannot accurately identify objects or determine positions for autonomous load handling
Solution Approach 1:
The sensing system is divided into multiple independent camera units (first camera on load backrest, second camera on tower) and sensor units (fork tip sensors, side sensors), each responsible for specific detection zones. This segmentation allows the system to achieve comprehensive coverage and high measurement precision without requiring a single complex sensing device.
2Adaptability or versatility
If multiple cameras and sensors are added to achieve comprehensive field of view, then object detection capability improves, but the device complexity increases
Solution Approach 1:
The camera system is designed to perform multiple functions: identifying objects, determining positions, verifying load engagement, and monitoring fork alignment. The same camera units serve both navigation and load handling functions, reducing the need for separate specialized devices and minimizing overall system complexity while maintaining high adaptability.
3Productivity
If autonomous control systems are implemented, then operational efficiency increases, but the control system complexity increases
Solution Approach 1:
The system continuously receives feedback from cameras and sensors about object positions, fork locations, and load engagement status. This feedback is processed by the controller to automatically adjust fork movement and vehicle navigation, enabling autonomous operation without requiring complex manual intervention systems.
4Manufacturing precision
If precise fork positioning is achieved through multiple sensors, then load engagement accuracy improves, but the cost and complexity of the system increases
Solution Approach 1:
The camera system acts as an intermediary between the control system and the physical fork position. Instead of directly measuring fork position with complex mechanical sensors, the system uses visual data from cameras to determine fork location and alignment, achieving high positioning precision through optical measurement rather than direct mechanical sensing.
Data Source
AI summary
A load handling module for a material handling vehicle can include a first camera configured to determine the position of an object in a first camera field of view, and a second camera positioned above the first camera and configured to determine the position of an object in a second camera field of view. A fork tip sensor can be secured to at least one fork proximate the tip end thereof, and can be configured to detect the presence of an object within a fork sensor field of view extending in front of the fork. A controller can be in communication with the first sensor, the second sensor, and the fork tip sensor, the controller being configured to autonomously control the material handling vehicle to pick up or drop-off a load.