Multi-Zone Obstacle Sensing for Warehouse Vehicle Speed Control
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Solution Overview
Problem
Operators of low-level order picking trucks in warehouses spend significant time relocating the vehicle during stock picking operations, reducing efficiency due to the need to repeatedly position the truck at different locations for picking stock.
Innovation Solution
A materials handling vehicle equipped with multiple detection zones and a controller that uses contactless obstacle sensors to differentiate between zones, allowing for specific actions based on obstacle detection, such as stopping or reducing speed, to enhance navigation and reduce unnecessary repositioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the operator manually relocates the vehicle to different positions for picking stock, then the operator can access stock at various locations, but the time spent on relocation increases and operational efficiency decreases
Solution Approach 1:
The detection space in front of the vehicle is segmented into multiple detection zones (first detection zone, second detection zone, third detection zone) with different distances from the vehicle. Each zone triggers different actions, allowing the vehicle to navigate more efficiently by making decisions based on the specific zone where an obstacle is detected, rather than using a single uniform detection threshold.
Solution Approach 2:
The system performs preliminary detection of obstacles at multiple distance thresholds before the vehicle reaches them. By detecting obstacles in advance at different zones and taking appropriate actions (stopping, slowing down, or continuing), the system prevents the need for frequent stopping and repositioning, thereby reducing relocation time and improving operational efficiency.
2Adaptability or versatility
If a single detection zone is used for obstacle detection, then the system is simple to implement, but the vehicle cannot differentiate between obstacles at different distances and cannot optimize navigation accordingly
Solution Approach 1:
The detection space is divided into multiple segments (detection zones) at different distances from the vehicle. The first detection zone is at a first distance, the second detection zone is at a second distance greater than the first, and the third detection zone is at a third distance greater than the second. This segmentation allows the system to adapt its navigation behavior based on the specific zone where an obstacle is detected.
Solution Approach 2:
Each detection zone has a different quality or characteristic (different distance thresholds) that determines the appropriate response. The system applies different actions locally based on which zone contains the obstacle: stopping for obstacles in the first zone, slowing down for obstacles in the second zone, or continuing for obstacles in the third zone. This local differentiation enhances navigation adaptability without requiring overly complex system architecture.
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
The system improves operational efficiency by allowing the vehicle to navigate more effectively under remote control, reducing time spent on relocation and increasing the time available for picking stock, while also enabling safer operation by avoiding obstacles.
Implementation Method 1
at least one contactless obstacle sensor on the vehicle and a controller. The obstacle sensor(s) are operable to define at least two detection zones
Data Source
AI summary
A materials handling vehicle includes at least one contactless obstacle sensor that scans at least two speed zones, each speed zone being defined in an area at least partially in front of a forward traveling direction of the vehicle and being associated with a unique predetermined maximum speed greater than zero (0) miles per hour. A controller that receives information obtained from the at least one obstacle sensor and, if the vehicle is traveling under remote control, the controller is configured to limit the vehicle speed to the predetermined maximum speed of a corresponding one of the at least two speed zones based upon the detection of an obstacle in that speed zone.