Racking Collision Classification Using Truck Status Data
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Solution Overview
Problem
Existing collision warning systems for racking systems suffer from false alarms due to the use of a single predetermined limit value for all collision types, leading to maintenance and resource inefficiencies, and lack precise classification of collision events.
Innovation Solution
A method and system that utilize a sensor on the racking system to detect collision events, determine their strength, and classify them based on both the collision strength and status data from the industrial truck, including movement data, to assign a specific collision type, using a combination of sensors and receivers in the truck to analyze and classify the event.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single predetermined limit value is used for all collision types, then the system is simple to operate, but false alarms increase and reliability decreases
Solution Approach 1:
The patent segments collision detection into two parts: a simple sensor unit on the racking system that detects collision strength, and a classification unit in the industrial truck that categorizes the collision type using status data. This segmentation allows the sensor unit to remain simple while the classification handles the complexity of distinguishing collision types, thereby reducing false alarms without complicating the detection device.
Solution Approach 2:
The patent implements dynamic threshold adjustment based on collision type classification. Instead of using a fixed threshold for all collisions, the system adapts the evaluation criteria according to the classified collision type (e.g., stacking collision vs. driving collision). This dynamic approach improves reliability by accurately distinguishing between harmful collisions and normal operational forces.
2Measurement precision
If complex classification analysis is performed on the racking system, then collision event precision improves, but energy consumption increases
Solution Approach 1:
The patent extracts the complex classification functionality from the racking system's sensor unit and relocates it to the industrial truck's control unit. The sensor unit only performs simple collision detection and strength measurement, consuming minimal energy. The detailed classification using status data is performed in the truck, which has its own power source. This extraction resolves the contradiction by maintaining precision while minimizing energy consumption at the racking system.
Solution Approach 2:
The patent introduces a communication interface as an intermediary between the sensor unit and the classification unit. The sensor unit transmits only essential collision data (strength, timestamp) to the truck's control unit, which then performs the complex classification. This intermediary approach allows precise classification without requiring the sensor unit to have high computational power or energy consumption.
3Measurement precision
If comprehensive status data is collected from the industrial truck, then classification accuracy improves, but device complexity increases
Solution Approach 1:
The patent leverages the existing multi-functional status data already collected by the industrial truck for other purposes (navigation, operation monitoring, safety). The same sensors and data collection systems used for general truck operation are also utilized for collision classification. This universal use of existing data and systems improves classification accuracy without adding significant device complexity, as the infrastructure already exists for these measurements.
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
Enables reliable and precise classification of collision events, reducing false alarms and optimizing maintenance by distinguishing between different collision types, such as driving and storage collisions, with low energy consumption on the racking system and minimal impact on the industrial truck's battery life.
Implementation Method 1
a sensor unit arranged on a racking system detects a collision event between an industrial truck and the racking system and determines a strength of the collision event
Data Source
AI summary
A method of classifying a collision event on a racking system including: detecting the collision event between an industrial truck and the racking system using a sensor on the racking system and determining a strength of the collision event, comparing the strength with a reference strength and emitting a collision signal if the determined strength exceeds the reference strength; transmitting the collision signal to a receiver of the industrial truck and forwarding the collision signal to a controller of the industrial truck, classifying the collision event as a function of status data of the industrial truck and of the collision signal. The classifying of the collision event comprises assigning a collision type from a collision type list, including at least one collision type for which the collision event is not assigned to the industrial truck and for which the collision event is assigned to the industrial truck.