Optical Gesture Control for Forklift Order Picking
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Solution Overview
Problem
Existing methods for controlling industrial trucks during order picking, such as radio gloves and voice command systems, face issues like user acceptance, frequent replacement costs, and inflexibility due to complex installations, which hinder efficient operation and require extensive training.
Innovation Solution
An optical sensor-connected control device tracks a person's position within a defined monitoring area, allowing the industrial truck to automatically follow the person's movements, eliminating the need for manual control and complex installations, and enabling flexible operation without additional devices or training.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If radio gloves are used for controlling the industrial truck, then the truck can be controlled remotely, but the gloves wear out through daily handling and must be replaced regularly, causing additional running costs
Solution Approach 1:
The patent replaces the mechanical radio glove control system with an optical sensing system. The control device uses optical sensors to detect the operator's hand gestures and body movements, automatically translating them into truck control commands. This eliminates the need for physical radio gloves that wear out, while maintaining remote control capability through non-contact optical detection of the operator's intentions.
2Ease of operation
If voice command systems are used for controlling the industrial truck, then the truck can be controlled through voice input, but background noise can be disruptive and additional location information is required
Solution Approach 1:
The patent replaces the acoustic voice command system with an optical gesture recognition system. The control device uses optical sensors to detect and interpret the operator's hand gestures and body movements, translating them into truck control commands. This eliminates susceptibility to background noise interference while maintaining hands-free operation capability, and does not require additional location information systems.
3Extent of automation
If partially automated systems with voice input are used, then the industrial truck can be automatically guided, but complex installations are required including navigation systems, goods management system connections, and servers
Solution Approach 1:
The patent extracts and eliminates the complex infrastructure requirements from the automated guidance system. Instead of requiring navigation systems, goods management system connections, and servers, the invention uses a self-contained control device with optical sensors that directly detects the operator's gestures and automatically controls the truck. This maintains automatic guidance capability while removing all complex installation requirements.
Solution Approach 2:
The control device performs all processing and control functions locally without requiring external servers or complex system connections. The optical sensors, processing unit, and actuator work together as an integrated self-sufficient system that automatically detects gestures and controls the truck independently, eliminating the need for external infrastructure.
4Ease of operation
If manual control is used for the industrial truck during order picking, then the picker can directly control the truck, but the picker has to repeatedly move to the control handle to actuate driving switches, consuming considerable time
Solution Approach 1:
The patent replaces the manual mechanical control system with an automated optical gesture recognition system. The control device continuously monitors the operator's hand gestures and body movements through optical sensors, automatically translating them into truck control commands without requiring the operator to physically reach for or manipulate control switches. This maintains direct control responsiveness while eliminating time loss from repeated movements to the control handle.
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
This solution allows for efficient, flexible, and cost-effective partially automated order picking, reducing operational time and training requirements, as the industrial truck automatically tracks the person's movements, enhancing productivity and usability in warehouses.
Implementation Method 1
an optical sensor with a monitoring area which is connected to a control device, and the control device determines the position of a person inside by evaluating the data from the optical sensor of the monitoring area is determined and tracked
Data Source
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AI summary
In a method for controlling a forklift truck (1), particularly during order picking, wherein the forklift truck (1) has an optical sensor (5) with a monitoring area (7) which is connected to a control device, and the control device determines and tracks the position of a person (2) within the monitoring area (7) by evaluating the data of the optical sensor (5), at least one monitoring boundary (8) is defined within the monitoring area (7) and is detected by the control device when the position of the person (2) has exceeded the monitoring boundary (8), and the forklift truck (1) is moved by the control device via a drive mechanism until the position of the person (2) is again on the original side of the monitoring boundary (8).