Robotic Forklift Navigation With Visual and RFID Pallet Positioning

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Solution Overview

Problem

Modern inventory systems face inefficiencies in locating, identifying, and handling pallets within warehouses due to limitations in navigation precision and the need for manual intervention, especially indoors where GPS signals are blocked, leading to inaccuracies and increased operational costs.

Innovation Solution

The use of a combination of video capture and processing, 3D range measurement, and imaging technologies, along with barcode localization, allows automated material handling trucks to precisely locate and manipulate pallets, enabling accurate load pick-up, placement, and stacking operations, even in complex indoor environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If GPS-based navigation is used for material handling vehicles, then navigation speed and coverage area are improved, but navigation precision deteriorates indoors where GPS signals are blocked

Engineering Contradiction:

Improvenavigation speedVSAvoidnavigation precision

Core Design Contradiction:

SpeedVSMeasurement precision

Solution Approach 1:

The navigation system is segmented into multiple independent subsystems: GPS for outdoor coarse navigation, visual markers for mid-range positioning, and RFID tags for precise indoor location identification. Each subsystem operates independently in its optimal environment, with the system switching between them based on location context.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Visual markers and RFID tags serve as intermediary positioning elements that bridge the gap between GPS outdoor navigation and precise indoor positioning. These markers act as reference points that the vehicle's camera and RFID reader can detect to determine exact location when GPS signals are unavailable.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If manual operation is used for pallet handling, then flexibility and adaptability are improved, but productivity and operational efficiency deteriorate

Engineering Contradiction:

Improveoperational flexibilityVSAvoidoperational efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system enables automated self-service operation where the material handling vehicle autonomously navigates to pallet locations, identifies targets using visual and RFID markers, executes picking/placement operations, and returns to storage areas without continuous manual intervention. Operators only need to monitor and intervene when exceptional situations arise.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If automated marker-based navigation is used indoors, then navigation precision is improved, but system complexity and infrastructure requirements worsen

Engineering Contradiction:

Improveindoor navigation precisionVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system uses inexpensive, easily deployable visual markers and RFID tags that can be placed on existing pallets and storage locations without requiring permanent infrastructure modifications. These markers are simple printed patterns or stickers that can be applied and removed as needed, avoiding complex installation requirements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of operation

If traditional forklifts are used for vertical stacking, then ease of operation is improved, but measurement precision and handling accuracy deteriorate

Engineering Contradiction:

Improveoperational simplicityVSAvoidpallet placement precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system incorporates real-time feedback through RFID readers that scan and verify pallet identification tags during handling operations. The controller receives feedback on pallet location, identity, and status, automatically adjusting operations to ensure precise placement and proper stacking sequences without requiring operator skill adjustments.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS11748700B2Automated warehousing using robotic forklifts or other material handling vehicles

Publication Date: 2023.09.05 CYBERNET SYSTEMS CORP

AI summary

Automated inventory management and material (or container) handling removes the requirement to operate fully automatically or all-manual using conventional task dedicated vertical storage and retrieval (S&R) machines. Inventory requests Automated vehicles plan their own movements to execute missions over a container yard, warehouse aisles or roadways, sharing this space with manually driven trucks. Automated units drive to planned speed limits, manage their loads (stability control), stop, go, and merge at intersections according human driving rules, use on-board sensors to identify static and dynamic obstacles, and human traffic, and either avoid them or stop until potential collision risk is removed. They identify, localize, and either pick-up loads (pallets, container, etc.) or drop them at the correctly demined locations. Systems without full automation can also implement partially automated operations (for instance load pick-up and drop), and can assure inherently safe manually operated vehicles (i.e., trucks that do not allow collisions).