Steer Correction Maneuvers for Materials Handling Vehicles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for steer correction in materials handling vehicles, such as low-level order picking trucks, are inefficient and require significant operator intervention, leading to reduced picking time due to frequent relocation and repositioning of the vehicle.
Innovation Solution
Implementing a system where sensor data from obstacle sensors is used by a controller to automatically perform steer correction maneuvers, adjusting the steering angle based on the proximity of detected objects to the vehicle, allowing the vehicle to autonomously navigate and avoid obstacles, thereby reducing the need for operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual steer correction is used by the operator, then the vehicle can be controlled to avoid obstacles, but the operator intervention increases and picking time decreases
Solution Approach 1:
The vehicle performs steer correction autonomously using sensor data and control algorithms without requiring operator intervention. The system detects objects in the environment, calculates appropriate steer correction angles, and automatically adjusts the steering to avoid obstacles while maintaining forward motion, thereby freeing the operator to focus on picking tasks
Solution Approach 2:
The manual mechanical steering control is replaced with an automated control system that uses sensors, processors, and actuators to perform steer correction. The system substitutes human operator actions with an automated feedback control loop that continuously monitors the environment and adjusts steering accordingly
2Reliability
If frequent steer correction maneuvers are performed, then obstacle avoidance is achieved, but vehicle repositioning time increases and picking efficiency decreases
Solution Approach 1:
The system applies partial steer correction only when and where needed based on object detection, rather than performing continuous or excessive steering adjustments. The control algorithm calculates the minimum necessary correction angle to avoid detected objects while maintaining overall forward progress, reducing unnecessary vehicle repositioning
Solution Approach 2:
The system dynamically adjusts the steer correction angle parameter based on the distance and position of detected objects. When objects are detected in outer regions, a first (smaller) correction angle is applied; when objects are in inner regions, a third (larger) correction angle is applied, optimizing the balance between obstacle avoidance and maintaining forward motion
3Productivity
If automated steer correction is implemented, then operator workload is reduced and picking efficiency increases, but system complexity increases
Solution Approach 1:
The control system integrates multiple functions into a single automated steer correction module that performs object detection, distance calculation, correction angle determination, and steering control. This multi-functional approach consolidates what would otherwise require separate systems, managing complexity while achieving automated obstacle avoidance
Solution Approach 2:
The system uses sensor feedback to continuously monitor the environment and adjust steer correction in real-time. The feedback loop provides the control system with object position and distance information, enabling automated adjustments without requiring complex predictive modeling or extensive pre-programming
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A materials handling vehicle automatically implements steer maneuvers when objects enter an environment around the vehicle. A steer correction maneuver is automatically performed by steering the vehicle away from the detected object, wherein an angle of steer correction and/or a rate of change of the steering angle that is implemented to achieve a desired angle of steer correction is dependent upon how far from a reference coordinate associated with the vehicle the detected object is determined to be, wherein the reference coordinate is a central axis of the vehicle.