Wireless Remote Control for Order Picking Trucks
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Solution Overview
Problem
Operators of low-level order picking trucks face inefficiencies due to the need to frequently relocate the vehicle, disrupting the picking process and requiring them to step off the truck to access jog switches, which reduces productivity and increases time spent repositioning rather than picking stock.
Innovation Solution
A supplemental remote control system that allows operators to wirelessly control the truck's movement using a wearable transmitter, enabling the truck to be remotely operated without the need to physically interact with the control handles, thereby allowing continuous operation and reducing the need for frequent repositioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the operator uses jog switches on the truck to relocate the vehicle, then the truck can be moved to the next location, but the operator must interrupt picking and step off the truck, reducing productivity
Solution Approach 1:
The control functions are extracted from the physical truck and placed into a portable remote control device. This allows the operator to control the truck's movement remotely while remaining at the picking location, eliminating the need to interrupt picking operations to relocate the vehicle.
Solution Approach 2:
A wireless remote control device serves as an intermediary between the operator and the truck. The operator communicates movement commands to the truck through this intermediary device, enabling continuous picking operations while the truck is relocated remotely.
2Ease of operation
If the operator steps off the truck to access jog switches, then the truck can be repositioned, but the operator loses control and must return to the truck, disrupting workflow
Solution Approach 1:
The mechanical control system requiring physical contact with the truck is replaced with a wireless electronic control system. The operator uses a portable transmitter that communicates wirelessly with the truck's receiver, eliminating the need to physically touch or be near the truck's control mechanisms.
3Adaptability or versatility
If the truck is moved frequently to reach different stock locations, then all orders can be picked, but the time available for actual picking is reduced
Solution Approach 1:
The truck can be preliminarily positioned near the starting location, and then remotely moved to subsequent locations as needed. The remote control capability allows the operator to prepare the truck's position in advance without interrupting the picking workflow at each location.
Data Source
AI summary
A method of associating a transmitter and a receiver in a supplemental remote control system for materials handling vehicles includes initiating a power on sequence to enable a vehicle for operation, the vehicle having a receiver for receiving wirelessly transmitted travel commands, and pairing and synchronizing the receiver and a corresponding vehicle controller to a select one of a plurality of wireless remote control devices. Pairing mode confidence signals are received at the vehicle receiver, wherein each pairing mode confidence signal provides a transmitter identification that uniquely identifies a corresponding wireless remote control device within range of the receiver. A known transmitter identification code associated with the select wireless remote control device is matched with a corresponding one of the pairing mode confidence signals received by the receiver, and the matched wireless remote control device is synchronized to the receiver and the controller of the vehicle for communication therebetween.