Obstacle Detection Speed Control for Order Picking Trucks
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Solution Overview
Problem
Operators of low-level order picking trucks face inefficiencies in stock picking operations due to the need to frequently relocate the vehicle, which interrupts the picking process and reduces time available for picking stock, especially when the distance between pick locations is significant.
Innovation Solution
A materials handling vehicle equipped with obstacle detectors and a controller that adjusts speed based on detected objects and load weight, allowing for remote control and automatic navigation to reduce the need for operator intervention in relocating the truck, thereby optimizing picking efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the operator frequently relocates the vehicle between pick locations, then the truck can service multiple storage areas, but the picking process is interrupted and time is lost
Solution Approach 1:
The truck is equipped with automatic obstacle detection and navigation systems that enable it to relocate itself between pick locations without operator intervention. The obstacle detectors automatically identify objects in the path of travel, and the controller autonomously navigates the truck around obstacles, allowing the vehicle to service multiple storage areas continuously without interrupting the picking process
Solution Approach 2:
The obstacle detectors are positioned to detect objects in advance of the truck's path of travel. The controller receives distance signals and generates speed adjustment signals before the truck reaches obstacles, enabling proactive speed reduction or stopping to avoid collisions, thus maintaining continuous operation without interruption
2Measurement precision
If the operator manually controls the truck during relocation, then precise positioning is achieved, but operator intervention interrupts the picking process
Solution Approach 1:
The controller continuously receives distance signals from obstacle detectors and automatically adjusts the truck's speed based on real-time feedback. When objects are detected within a predetermined distance, the controller generates speed adjustment signals to reduce speed or stop, achieving precise positioning and obstacle avoidance without operator intervention, thereby maintaining continuous picking operations
Solution Approach 2:
The manual mechanical control system is replaced with an automated electronic control system. The controller uses electronic signals from obstacle detectors to automatically regulate truck speed and positioning, substituting the operator's manual mechanical steering and speed control with an automated feedback-based electronic control system that maintains both precision and continuous operation
3Speed
If the truck travels at high speed between locations, then relocation time is reduced, but safety risks increase when obstacles are present
Solution Approach 1:
The truck's speed is dynamically adjusted based on real-time obstacle detection. The controller continuously monitors distance signals from obstacle detectors and automatically modifies the speed command signal accordingly. The truck can travel at high speeds when paths are clear but automatically reduces speed or stops when obstacles are detected, maintaining both efficiency and safety through dynamic speed regulation
Solution Approach 2:
The obstacle detection system identifies potential hazards in advance of the truck's path of travel. The controller receives distance signals and generates speed adjustment signals before the truck reaches problematic areas, enabling proactive speed reduction or stopping to prevent collisions, thus maintaining safety while allowing high-speed travel in clear conditions
Data Source
AI summary
A materials handling vehicle includes a power unit; a load handling assembly coupled to the power unit; at least one obstacle detector mounted to the power unit; and a controller. The at least one obstacle detector detects object located along a path of travel of the power unit, and generate a distance signal upon detecting an object corresponding to a distance between the detected object and the power unit. The controller receives the distance signal and generates a corresponding vehicle stop or predetermined maximum allowable speed signal based on the distance signal, wherein if a sensed object is located within a speed zone associated with a predetermined maximum allowable travel speed comprising a fixed speed greater than zero (0) miles per hour, as determined by the distance signal, the vehicle speed is reduced to the predetermined maximum allowable vehicle speed.