Pallet Face Tracking for Smooth Fork Engagement and Release
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Solution Overview
Problem
Autonomous vehicles in warehouses often inadvertently push or drag pallets during engagement or disengagement due to inaccuracies in positioning or protrusions on the pallet, leading to improper pick-up or drop-off and potential damage.
Innovation Solution
A control system that uses sensor data to determine a baseline geometric representation of a pallet's face, comparing it to updated representations during engagement or disengagement, and adjusts the vehicle's motion to avoid pushing or dragging the pallet by modifying its position or path if significant deviations are detected, or by utilizing an exclusion field to monitor for unplanned repositioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the vehicle repositions the tines to engage or disengage from the pallet, then the pallet can be picked up or dropped off, but the vehicle may inadvertently push or drag the pallet due to positioning inaccuracies or protrusions
Solution Approach 1:
The system performs preliminary scanning of the pallet face using a sensor before engagement to identify protrusions and determine the correct engagement path. The vehicle then adjusts its motion in advance to avoid these protrusions, preventing pushing or dragging during the actual engagement or disengagement operation.
Solution Approach 2:
The sensor continuously monitors the pallet face during vehicle approach and engagement/disengagement. The control system compares real-time sensor data with the baseline geometric representation to detect any unintended pallet movement, providing feedback that allows the vehicle to adjust its motion to prevent pushing or dragging.
2Productivity
If the vehicle moves quickly to improve operational efficiency, then productivity increases, but the risk of pushing or dragging the pallet due to positioning errors increases
Solution Approach 1:
The system performs preliminary scanning and path planning before the vehicle engages the pallet at speed. By identifying protrusions and calculating an adjusted engagement path in advance, the vehicle can move quickly while still avoiding protrusions that would cause pushing or dragging and potential damage.
Solution Approach 2:
The sensor system continuously monitors pallet position during high-speed operations, providing real-time feedback to the control system. This allows the vehicle to maintain high speed while dynamically adjusting its motion to prevent harmful interactions with the pallet.
Data Source
AI summary
An example method may include receiving, from a sensor on a vehicle, an initial plurality of sensor data points representing a position of a face of a pallet. The vehicle may include tines configured to engage the pallet. A baseline geometric representation of the face of the pallet may be determined based on the initial plurality of sensor data points. The vehicle may be caused to reposition the tines relative to the pallet. A subsequent plurality of sensor data points representing the position of the face of the pallet after repositioning the tines may be received from the sensor. An updated geometric representation of the face of the pallet may be determined based on the subsequent sensor data points. It may be determined that the updated geometric representation deviates from the baseline geometric representation by more than a threshold value and, in response, motion of the vehicle may be adjusted.