Picking Vehicle Camera Leveling for Ergonomic Load Placement
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Solution Overview
Problem
Existing order picking systems face challenges in automatically adjusting the lifting height of load-handling devices to ergonomically optimal levels, particularly when dealing with load carriers having side walls or varying load heights, leading to inefficiencies and increased physical strain on pickers.
Innovation Solution
A method utilizing a portable camera device worn by the picker to detect storage heights and physical characteristics, transmitting data to a control unit on the vehicle to adjust the lifting height of the load-handling device ergonomically, ensuring precise and ergonomic placement of objects on target load carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If automatic leveling devices with sensors are used to adjust the lifting height of the load-handling device, then the ergonomics of loading and unloading is improved, but the device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical sensor systems with a camera-based optical system. The camera device captures images of the load carrier and deposit position, and image processing algorithms automatically determine the deposit height, eliminating the need for complex mechanical sensors and leveling mechanisms while maintaining ergonomic benefits.
Solution Approach 2:
The patent uses a camera to create an optical copy (image) of the physical load carrier and deposit position. This visual copy is then processed to extract height information, replacing the need for direct physical measurement systems and reducing mechanical complexity.
2Reliability
If traditional sensor devices are used for automatic leveling, then the lifting height can be adjusted, but they fail to work correctly with load carriers having side walls
Solution Approach 1:
The patent transitions from horizontal/oblique sensor detection (which fails with side walls) to vertical camera-based optical detection. By capturing images from above and processing them to extract height information, the system can accurately measure deposit heights regardless of side wall presence, as the camera views the top surface rather than the sides.
Solution Approach 2:
The patent replaces mechanical sensors that physically interact with the load carrier structure with an optical camera system. This allows the system to detect deposit heights on various load carrier types (including those with side walls) without mechanical interference, significantly improving adaptability while maintaining detection accuracy.
3Productivity
If manual height adjustment is used, then the system remains simple, but the picker experiences physical strain and takes longer to complete tasks
Solution Approach 1:
The system performs automatic height detection and adjustment without requiring manual intervention from the picker. The camera device automatically captures images, the control unit processes them to determine optimal deposit heights, and the lifting device automatically adjusts to these heights, eliminating the need for the picker to manually adjust heights and reducing physical strain.
Solution Approach 2:
The system uses camera-based feedback to automatically detect the current load carrier state and adjust the lifting height accordingly. The camera continuously monitors the deposit position, and the control unit uses this feedback to automatically adjust the lifting device to the optimal height, improving productivity while eliminating physical strain on the picker.
4Ease of operation
If automatic leveling is implemented, then ergonomic loading is achieved, but additional time is required for the leveling operation
Solution Approach 1:
The camera device captures images of the load carrier and deposit position in advance, and the control unit processes these images to determine the optimal deposit height before the actual picking operation begins. This preliminary detection and calculation eliminates the need for time-consuming adjustments during the picking process, maintaining ergonomics while reducing time loss.
Solution Approach 2:
The patent replaces slow mechanical sensor-based leveling systems with rapid camera-based optical detection and image processing. The camera can quickly capture images and the control unit can rapidly process them to determine deposit heights, significantly reducing the time required for the leveling operation while maintaining ergonomic benefits.
Data Source
Figure 1
AI summary
The invention relates to a method for picking at least one object, in particular a product and/or a production part, with a picking vehicle (1) having a load handling device (2) that can be raised and lowered by a lifting device (4), in particular a load fork (3), wherein during a picking operation the object is placed in a depositing operation from outside the picking vehicle (1) onto a target load carrier (5, 6) arranged on the load handling device (2) at a depositing position at a depositing height, wherein an automatic leveling of the lifting height of the load handling device (2) is carried out.It is proposed that a camera device (15), worn by a picker (14) performing the placement operation, captures the placement height of the item during each placement operation and transmits information about the captured placement height to a control unit (10), in particular a data processing unit, which controls the leveling of the lifting height of the load handling device (2) depending on the information about the captured placement height. The invention further relates to a picking system for carrying out the method.