Industrial Vehicle Data Acquisition via Portable Storage and Power Line Communication
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Solution Overview
Problem
Existing material handling vehicles in industrial settings face challenges in efficient data communication and unauthorized operation prevention, with costly wiring harnesses and limited communication networks, especially in smaller facilities, and require effective mechanisms for monitoring operator productivity and vehicle maintenance.
Innovation Solution
The implementation of a communication network using a portable storage device like a USB flash drive for authorization and a power line communication system with electrical chokes, along with a data acquisition module and interface module for compatible data transmission, enables secure and efficient data exchange between industrial vehicles and central computer systems, allowing for authorized operation and performance monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wiring harness is installed to connect sensors and data collection computer, then data communication is enabled, but installation time and cost increase significantly
Solution Approach 1:
The patent extracts the data communication function from the traditional wiring harness infrastructure and relocates it to a portable storage device. The data collection computer reads operational data directly from the portable storage device inserted into the vehicle's controller, eliminating the need for extensive wiring harness installation while maintaining full data communication capability.
Solution Approach 2:
The portable storage device serves as an intermediary between the vehicle's controller and the data collection computer. It stores operational data locally and allows the data collection computer to retrieve information without requiring a direct wired connection, thus solving the communication problem without the time-consuming wiring installation.
2Reliability
If a centralized local area communication network with wireless transceivers is deployed, then data transmission is enabled, but system cost becomes prohibitive for small facilities
Solution Approach 1:
The patent extracts the data transmission function from the complex centralized network infrastructure and implements it through a simple portable storage device. The data collection computer directly reads from the portable storage device without requiring wireless transceivers, network servers, or other expensive infrastructure components.
Solution Approach 2:
The portable storage device is a low-cost, simple component compared to the expensive network infrastructure. It can be easily replaced or updated without investing in costly network equipment, making the system economically viable for small facilities with limited budgets.
3Reliability
If traditional wired sensor connection is used, then data collection is reliable, but retrofitting existing vehicles becomes expensive and complex
Solution Approach 1:
The patent extracts the data collection function from the vehicle's internal wiring system and implements it externally through a portable storage device. This allows retrofarming existing vehicles without modifying their internal wiring or controller architecture, significantly reducing retrofitting complexity and cost.
Solution Approach 2:
The portable storage device serves as a universal interface that can be inserted into various vehicle controllers without customization. The data collection computer is configured to read from this standard interface, making the system adaptable to different vehicle types without requiring vehicle-specific wiring modifications.
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
This solution reduces wiring costs, enhances data transmission efficiency, and ensures authorized operation while providing comprehensive performance data analysis for optimizing warehouse operations, improving productivity and maintenance scheduling.
Implementation Method 1
a communication network conveys data and commands among the operator input devices, the controller, the sensors, and other vehicle components
Implementation Method 2
a power line communication system with electrical chokes
Data Source
AI summary
Operation of an industrial vehicle is managed by systems onboard that vehicle. One such management system monitors operation of vehicle components and produces performance data which is transmitted to an computer at the facility in which the industrial vehicle operates. That system includes an interface module with a plurality of inputs for receiving signals from components on the industrial vehicle. The interface module derives performance data from the signals and conveys the performance data over a communication network. A data acquisition module receives the performance data from the communication network and has a communicator for wirelessly transmitting the performance data.