Steer Correction for Remotely Operated Materials Handling Vehicle
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Solution Overview
Problem
Low level order picking trucks require significant operator time for relocating and repositioning, reducing the time available for picking stock due to the need for manual steering and navigation in warehouse environments.
Innovation Solution
A system for automatically applying steer correction maneuvers to materials handling vehicles using remote sensing devices, such as scanning lasers and ultrasonic sensors, to detect obstacles and adjust the vehicle's path, allowing for autonomous steering and reduced operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual steering and navigation is used by operator, then the truck can be controlled in warehouse environments, but operator time spent on relocating and repositioning increases, reducing time available for picking stock
Solution Approach 1:
The truck is equipped with remote sensing devices (scanning lasers, ultrasonic sensors) and a controller that automatically detect obstacles and perform steer correction maneuvers without operator intervention. The system serves itself by autonomously navigating around obstacles in warehouse environments, eliminating the need for manual steering corrections and allowing the operator to focus solely on picking stock.
2Extent of automation
If remote sensing devices and automatic steer correction system are added, then operator intervention for steering is reduced, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it processes data from scanning lasers, ultrasonic sensors, and other vehicle systems; it determines when steer correction is needed; and it controls the steering mechanism. By making the controller multi-functional, the patent avoids adding separate dedicated units for each function, thereby managing system complexity while achieving autonomous steering capability.
3Ease of operation
If steer correction maneuvers are applied automatically, then operator time for manual steering is reduced, but the system requires continuous sensor monitoring and processing
Solution Approach 1:
The system continuously monitors the environment using scanning lasers and ultrasonic sensors, processes the sensor data to detect obstacles in the steer bumper zones, and automatically adjusts steering accordingly. This closed-loop feedback system maintains ease of operation by handling all steering decisions automatically while using integrated sensor processing to manage complexity.
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
The system enhances operational efficiency by minimizing the need for manual steering, reducing operator time spent on repositioning the truck and allowing for continuous stock picking, thereby increasing overall order fulfillment speed.
Implementation Method 1
receiving first sensor data from at least one remote sensing device, by a controller on a materials handling vehicle
Implementation Method 2
at least one remote sensing device, such as scanning lasers and ultrasonic sensors
Data Source
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AI summary
A materials handling vehicle (10) automatically applies a steer correction maneuver if an object (172) is detected in a steer bumper zone (132) in front of the vehicle. A controller detects whether an object is in front of the materials handling vehicle and automatically determines whether a steer correction maneuver should be to the right or left of the traveling direction of the materials handling vehicle. The materials handling vehicle automatically steer corrects the vehicle, e.g., at a determined steer angle that is opposite the direction to the detected position of the object, and accumulates the distance traveled by vehicle while steer correction is being performed. The vehicle then automatically counter steers the vehicle, e.g., by a determined steer amount, in the opposite direction as the steer correction for a percentage of accumulated steer distance traveled. After performing the counter steer maneuver, the vehicle may, for example, resume a substantially straight heading.