Tugger Train Trailer Optical Positioning for Precise Load Transfer
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Solution Overview
Problem
Conventional positioning systems for autonomously operated tugger trains are inaccurate and costly, making precise load transfer between tugger train trailers and stationary transfer stations challenging.
Innovation Solution
A system comprising two light barriers on the tugger train trailer and a reflector at the stationary transfer station, which interact to control the tugger train's positioning with high accuracy and low cost, allowing precise alignment in the longitudinal direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional positioning systems with laser scanners and reflectors are used, then positioning capability is provided, but accuracy is too low for autonomous tugger trains
Solution Approach 1:
The patent replaces conventional laser scanners with a light barrier system that uses optical fields instead of mechanical scanning components. The light barrier with transmitter and receiver creates an optical detection field that directly measures position without moving parts, achieving higher accuracy and reliability for autonomous positioning.
Solution Approach 2:
The patent uses a reflector to create an optical copy of the light barrier signal. The reflector positioned at the transfer station reflects the light barrier's optical field back to the receiver, creating a virtual detection point that enables precise positioning without requiring the receiver to be physically located at the transfer station.
2Measurement precision
If conventional positioning systems with magnetic strips on roadway are used, then positioning capability is provided, but installation complexity and costs are high
Solution Approach 1:
The patent extracts the positioning function from the roadway infrastructure (magnetic strips) and relocates it to the tugger train itself through the light barrier system. This eliminates the need for complex roadway modifications while maintaining positioning accuracy, as the light barrier components are mounted on the vehicle rather than embedded in the infrastructure.
Solution Approach 2:
The light barrier system serves multiple functions: it provides positioning accuracy, works on existing roadway surfaces without modification, and can be used across different transfer station locations. The reflector at the transfer station serves as a universal reference point that works with any tugger train equipped with the light barrier system.
3Measurement precision
If manual positioning with laser pointer is used, then positioning capability is provided, but automation is not achieved
Solution Approach 1:
The patent implements self-service positioning where the tugger train's light barrier system automatically detects the reflector at the transfer station and determines its own position without human intervention. The system autonomously measures the distance and position based on optical field interactions, enabling fully automated positioning for driverless operation.
Solution Approach 2:
The patent creates a feedback loop where the light barrier continuously monitors the optical field reflection from the transfer station reflector. This real-time feedback provides continuous position information to the control system, enabling automated adjustment and maintenance of precise positioning without manual intervention.
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 precise and cost-effective positioning of tugger train trailers at transfer stations, facilitating accurate load transfer even in the absence of a driver, with a simple and fail-safe design.
Implementation Method 1
a reflector (15) at the stationary transfer station (5a-5d), which interacts with the light barriers (12a, 12b)
Data Source
Figure 1
Figure 2a~2b
Figure 2c~3a
AI summary
The invention relates to a system (1) comprising a tugger train (2), which has a towing vehicle (3) and at least one tugger train trailer (4a; 4b; 4c; 4d), and at least one stationary transfer station (5a; 5b; 5c; 5d) for transferring loads (L1; L2; L3; L4) between the tugger train trailer (4a; 4b; 4c; 4d) and the stationary transfer station (5a; 5b; 5c; 5d), wherein, in order to transfer loads, the tugger train trailer (4a; 4b; 4c; 4d) is located in a defined reloading position relative to the stationary transfer station (5a; 5b; 5c; 5d). The tugger train trailer (4a; 4b; 4c; 4d) has two light beams (LS1, LS2) which are spaced apart from each other in the longitudinal direction (F) of the tugger train trailer (4a; 4b; 4c; 4d) and which are arranged on the tugger train trailer (4a; 4b; 4c; 4d) in each case with a detection direction aligned in a transverse direction (Q) of the tugger train trailer (4a; 4b; 4c; 4d), and the stationary transfer station (5a; 5b; 5c; 5d) is provided with a reflector (RF) which cooperates with the light beams (LS1, LS2). The light beams (LS1, LS2) are operatively connected to a drive control (40) of the tugger train (2) and the drive control (40) is designed such that, by means of the light signals reflected by the light beams (LS1, LS2) on the reflector (RF), the tugger train trailer (4a; 4b; 4c; 4d) is stopped at the stationary transfer station (5a; 5b; 5c; 5d) in the defined reloading position.