Load Handling Module for Autonomous Material Vehicles
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Solution Overview
Problem
Material handling vehicles face challenges in autonomously loading and unloading loads in various locations, including on racks or the floor, due to limited sensing capabilities and precise positioning requirements.
Innovation Solution
A load handling module equipped with cameras and sensors that provide 3D imaging and object detection, allowing for precise control of fork positioning and movement, enabling autonomous pick-up and drop-off operations by determining load position, orientation, and surrounding space, with adjustable camera configurations and sensors at fork tips for enhanced accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If material handling vehicles use basic sensing capabilities, then the device complexity is reduced, but the measurement precision and positioning accuracy deteriorate
Solution Approach 1:
The sensing system is divided into multiple independent components: cameras mounted at specific locations on the vehicle, sensors integrated into the fork assembly, and processing units distributed throughout the system. This segmentation allows each component to perform a specific function with high precision while maintaining overall system manageability.
Solution Approach 2:
The patent introduces intermediate processing layers including image processing algorithms that translate camera images into spatial information, and control algorithms that convert sensor data into positioning commands. These intermediaries bridge the gap between basic sensing components and precise positioning requirements.
2Extent of automation
If material handling vehicles use simple control systems, then the device complexity is reduced, but the autonomous loading and unloading capability deteriorates
Solution Approach 1:
The control system is designed to autonomously perform loading and unloading operations without human intervention. The vehicle independently processes sensor data, determines optimal fork positioning, executes pick-up and drop-off maneuvers, and navigates to various locations including racks and floors, thereby achieving self-service autonomous operation.
Solution Approach 2:
The system incorporates continuous feedback loops where sensors monitor fork position and load status, cameras verify spatial relationships, and the control algorithm adjusts commands in real-time based on this feedback. This closed-loop control enables reliable autonomous operation despite the increased system complexity.
3Measurement precision
If material handling vehicles use limited sensing capabilities, then the device complexity is reduced, but the ability to determine load position and orientation deteriorates
Solution Approach 1:
The patent merges multiple sensing modalities including cameras mounted on the vehicle body and sensors integrated into the fork assembly. This combination of different sensing types complement each other to provide comprehensive load position and orientation detection capabilities that exceed what any single sensor could achieve alone.
Solution Approach 2:
The system transitions from basic 2D camera images to 3D spatial understanding by processing images from multiple camera angles and integrating sensor data. This dimensional enhancement allows precise determination of load position, orientation, and surrounding space in three-dimensional space.
Data Source
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AI summary
A load handling module 100 for a material handling vehicle 60 can include a first camera configured to determine the position of an object in a first camera 104 field of view, and a second camera 108 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 128 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 150 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.