MULTIPLE ZONE SENSING FOR MATERIALS HANDLING VEHICLES

• US 20100114405A1
• Filed: 12/04/2009
• Published: 05/06/2010
• Est. Priority Date: 09/14/2006
• Status: Active Grant

• Current Assignee: Crown Equipment Corporation
• Original Assignee: Crown Equipment Corporation
• Inventors: Elston, Edwin R., Jensen, Eric L., Siefring, Vernon W.
• Granted Patent: US 9,645,968 B2
• Time in Patent Office: Days
• US Class Current: 701/2
• CPC Class Codes: B60W 10/04 including control of propulsion units
• CPC Class Codes: B60W 10/20 including control of steering systems
• CPC Class Codes: B60W 2300/121 Fork lift trucks, Clarks
• CPC Class Codes: B60W 2540/215 Selection or confirmation of options
• CPC Class Codes: B60W 2554/00 Input parameters relating to objects
• CPC Class Codes: B60W 2710/20 Steering systems
• CPC Class Codes: B60W 2720/10 Longitudinal speed
• CPC Class Codes: B60W 30/09 Taking automatic action to avoid collision, e.g. braking and steering
• CPC Class Codes: B60W 50/08 Interaction between the driver and the control system
• CPC Class Codes: B66F 9/07509 Braking
• CPC Class Codes: B66F 9/0755 Position control; Position detectors
• CPC Class Codes: B66F 9/07568 Steering arrangements
• CPC Class Codes: B66F 9/07572 Propulsion arrangements
• CPC Class Codes: B66F 9/07581 Remote controls
• CPC Class Codes: G05D 1/0011 associated with a remote control arrangement
• CPC Class Codes: G05D 1/0033 by having the operator tracking the vehicle either by direct line of sight or via one or more cameras located remotely from the vehicle
• CPC Class Codes: G05D 1/0212 with means for defining a desired trajectory involving a plurality of land vehicles G05D1/0287
• CPC Class Codes: G05D 1/024 in combination with a laser lasers per se H01S
• CPC Class Codes: G05D 1/0255 using acoustic signals, e.g. ultra-sonic singals sonar systems designed for anti-collision purposes G01S15/93
• CPC Class Codes: G05D 2201/0216 Vehicle for transporting goods in a warehouse, factory or similar
• CPC Class Codes: G06F 17/00 : Digital computing or data processing equipment or methods, specially adapted for specific functions information retrieval, database structures or file system structures therefor G06F16/00
• CPC Class Codes: G08C 17/02 : using a radio link
• CPC Class Codes: G08C 2201/20 : Binding and programming of remote control devices

Abstract

A supplemental control system for a materials handling vehicle comprises one or more sensors capable of defining multiple contactless detection zones at least towards the front of the forward travel direction of a remotely controlled vehicle. The vehicle responds to the detection of objects within the designated zones based upon predetermined actions, such as to slow down or stop the vehicle, and/or to take other action, such as to perform a steer angle correction.

Claims

1. A materials handling vehicle having detection zone control comprising:

a power unit for driving the vehicle;

a load handling assembly that extends from the power unit;

at least one contactless obstacle sensor on the vehicle operable to define at least two detection zones, each detection zone defining an area at least partially in front of a forward traveling direction of the vehicle; and

a controller that is configured to control at least one aspect of the vehicle, the controller further configured to receive information obtained from the at least one obstacle sensor to;

perform a first action if the vehicle is traveling and an obstacle is detected in a first one of the detection zones; and

perform a second action different from the first action if the vehicle is traveling and an obstacle is detected in a second one of the detection zones.

2. The materials handling vehicle according to claim 1, wherein:

the controller communicates with a traction control system of the vehicle;

the first one of the detection zones comprises a stop zone;

the second one of the detection zones comprises a first speed zone;

the first action of the controller comprises a stop action;

the second action of the controller comprises a first speed reduction action;

the controller is configured to implement the stop action to stop the vehicle if the vehicle is traveling and an obstacle is detected in the stop zone; and

the controller is configured to implement the speed reduction action to reduce the speed of the vehicle to a first predetermined speed if the vehicle is traveling at a speed greater than the first predetermined speed and an obstacle is detected in the first speed zone.

3. The materials handling vehicle according to claim 2, wherein:

the at least two detection zones further comprises a third detection zone designating a second speed zone; and

the controller is further configured to implement a second speed reduction action to reduce the speed of the vehicle to a second predetermined speed if the vehicle is traveling at a speed greater than the second predetermined speed and an obstacle is detected in the second speed zone.

4. The materials handling vehicle according to claim 2, wherein:

the controller is further configured to refuse to operate the vehicle if an obstacle is detected within the stop zone before the vehicle begins travel.

5. The materials handling vehicle according to claim 1, wherein:

each detection zone is associated with an associated speed control zone and a corresponding maximum speed; and

the controller is further configured to limit the vehicle speed to the predetermined maximum speed of an associated speed control zone based upon the detection of an obstacle in that speed zone.

6. The materials handling vehicle according to claim 1, wherein:

the controller is further configured to modify at least one vehicle parameter other than speed in response to detecting an obstacle in at least one detection zone.

7. The materials handling vehicle according to claim 1, wherein the at least one contactless obstacle sensor comprises at least one laser sensor.

8. The materials handling vehicle according to claim 1, wherein:

the controller further communicates with a steer controller of the vehicle;

at least one of the detection zones comprises a steer angle correction zone; and

the controller is further configured to implement a steer angle correction if an obstacle is detected in a corresponding steer angle correction zone.

9. The materials handling vehicle according to claim 8, wherein the controller is further configured to select a direction of steer angle adjustment based upon a determination of a position of a detected obstacle.

10. The materials handling vehicle according to claim 9, wherein:

the at least two detection zones comprise a plurality different steer angle correction zones; and

the controller is further configured to implement a different steer angle correction amount for each steer angle correction zone.

11. A materials handling vehicle capable of supplemental remote control comprising:

a power unit for driving the vehicle;

a load handling assembly that extends from the power unit;

a receiver at the vehicle for receiving transmissions from a corresponding remote control device, the transmissions comprising at least a first type signal designating a travel request requesting the vehicle to travel;

at least one contactless obstacle sensor on the vehicle that is operable to define at least two detection zones, each detection zone defining an area at least partially in front of a forward traveling direction of the vehicle when the vehicle is traveling under remote control in response to a travel request; and

a controller that communicates with the receiver and with a traction control system of the vehicle to operate the vehicle under remote control in response to receiving travel requests from the remote control device, wherein the controller receives information obtained from the at least one obstacle sensor and is configured to;

perform a first action if the vehicle is traveling under remote control in response to a travel request and an obstacle is detected in a first one of the detection zones; and

perform a second action different from the first action if the vehicle is traveling under remote control in response to a travel request and an obstacle is detected in a second one of the detection zones.

12. The materials handling vehicle according to claim 11, wherein:

the first one of the detection zones comprises a stop zone;

the second one of the detection zones comprises a first speed zone;

the first action of the controller comprises a stop action;

the second action of the controller comprises a first speed reduction action;

the controller is configured to implement the stop action to stop the vehicle if the vehicle is traveling under remote control in response to a travel request and an obstacle is detected in the stop zone; and

the controller is configured to implement the speed reduction action to reduce the speed of the vehicle to a first predetermined speed if the vehicle is traveling under remote control in response to a travel request at a speed greater than the first predetermined speed and an obstacle is detected in the first speed zone.

13. The materials handling vehicle according to claim 12, wherein:

the at least two detection zones further comprises a third detection zone designating a second speed zone; and

the controller is further configured to implement a second speed reduction action to reduce the speed of the vehicle to a second predetermined speed if the vehicle is traveling under remote control in response to a travel request at a speed greater than the second predetermined speed and an obstacle is detected in the second speed zone.

14. The materials handling vehicle according to claim 12, wherein:

the controller is further configured to refuse to operate the vehicle under remote control in response to receipt of a travel request received from the remote control device if an obstacle is detected within the stop zone before the vehicle begins travel.

15. The materials handling vehicle according to claim 12, wherein:

the controller is further configured to accelerate the vehicle to a predetermined maximum speed that is greater than the first predetermined speed if the vehicle is traveling under remote control in response to a travel request and no obstacle is detected in the stop zone and no obstacle is detected in the first speed zone.

16. The materials handling vehicle according to claim 11, wherein:

the controller is further configured to modify at least one vehicle parameter other than speed in response to detecting an obstacle in at least one detection zone.

17. The materials handling vehicle according to claim 11, wherein the at least one contactless obstacle sensor comprises at least one laser sensor.

18. The materials handling vehicle according to claim 11, further comprising:

at least one presence sensor for detecting whether an operator is positioned on the vehicle, wherein the controller is further configured to operate the vehicle under remote control when the at least one presence sensor designates that no operator is on the vehicle.

19. The materials handling vehicle according to claim 11, wherein:

the controller further communicates with a steer controller of the vehicle;

one of the detection zones comprises a steer angle correction zone; and

the controller is further configured to implement a steer angle correction if an obstacle is detected in the steer angle correction zone.

20. The materials handling vehicle according to claim 19, wherein the controller is further configured to select a direction of steer angle adjustment based upon a determination of a position of a detected obstacle.

21. The materials handling vehicle according to claim 19, wherein:

the at least two detection zones comprise a plurality different steer angle correction zones; and

the controller is further configured to implement a different steer angle correction amount for each steer angle correction zone.

22. A multiple detection zone supplemental remote control system for a materials handling vehicle comprising:

a remote control device manually operable by an operator to wirelessly transmit at least a first type signal designating a travel request requesting the vehicle to travel by a predetermined amount;

a receiver for installation on the vehicle that receives transmissions from the corresponding remote control device;

at least one contactless obstacle sensor that is operable to define at least two detection zones, each detection zone defining an area at least partially in front of a forward traveling direction of the vehicle when the vehicle is traveling under remote control in response to a travel request; and

a controller that communicates with the receiver and with a traction control system of the vehicle to operate the vehicle under remote control in response to receiving travel requests from the remote control device, wherein the controller receives information obtained from the at least one obstacle sensor and is configured to;

perform a first action if the vehicle is traveling under remote control in response to a travel request and an obstacle is detected in a first one of the detection zones; and

perform a second action different from the first action if the vehicle is traveling under remote control in response to a travel request and an obstacle is detected in a second one of the detection zones.

23. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 22, wherein:

the first one of the detection zones comprises a stop zone;

the second one of the detection zones comprises a first speed zone;

the first action of the controller comprises a stop action;

the second action of the controller comprises a first speed reduction action;

the controller is configured to implement the stop action to stop the vehicle if the vehicle is traveling under remote control in response to a travel request and an obstacle is detected in the stop zone; and

the controller is configured to implement the speed reduction action to reduce the speed of the vehicle to a first predetermined speed if the vehicle is traveling under remote control in response to a travel request at a speed greater than the first predetermined speed and an obstacle is detected in the first speed zone.

24. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 23, wherein:

the at least two detection zones further comprises a third detection zone designating a second speed zone; and

the controller is further configured to implement a second speed reduction action to reduce the speed of the vehicle to a second predetermined speed if the vehicle is traveling under remote control in response to a travel request at a speed greater than the second predetermined speed and an obstacle is detected in the second speed zone.

25. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 23, wherein:

the controller is further configured to refuse to operate the vehicle under remote control in response to receipt of a travel request received from the remote control device if an obstacle is detected within the stop zone before the vehicle begins travel.

26. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 23, wherein:

the controller is further configured to accelerate the vehicle to a predetermined maximum speed that is greater than the first predetermined speed if the vehicle is traveling under remote control in response to a travel request and no obstacle is detected in the stop zone and no obstacle is detected in the first speed zone.

27. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 22, wherein:

the controller is further configured to modify at least one vehicle parameter other than speed in response to detecting an obstacle in at least one detection zone.

28. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 22, wherein:

the at least one contactless obstacle sensor comprises at least one laser sensor.

29. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 22, further comprising:

at least one presence sensor for detecting whether an operator is positioned on the vehicle, wherein the controller is further configured to operate the vehicle under remote control when the at least one presence sensor designates that no operator is on the vehicle.

30. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 22, wherein:

the controller further communicates with a steer controller of the vehicle;

one of the detection zones comprises a steer angle correction zone; and

the controller is further configured to implement a steer angle correction if an obstacle is detected in the steer angle correction zone.

31. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 30, wherein the controller is further configured to select a direction of steer angle adjustment based upon a determination of a position of a detected obstacle.

32. The multiple detection zone supplemental remote control system for a materials handling vehicle according to claim 30, wherein:

the at least two detection zones comprise a plurality of different steer angle correction zones; and

the controller is further configured to implement a different steer angle correction amount for each steer angle correction zone.

33. A multiple detection zone control system for a materials handling vehicle comprising:

at least one contactless obstacle sensor that is operable to define at least two detection zones, each detection zone defining an area at least partially in front of a forward traveling direction of the vehicle when the vehicle is traveling; and

a controller that is configured to integrate with and control at least one aspect of the vehicle, the controller further configured to receive information obtained from the at least one obstacle sensor to;

perform a first action if the vehicle is traveling and an obstacle is detected in a first one of the detection zones; and

perform a second action different from the first action if the vehicle is traveling and an obstacle is detected in a second one of the detection zones.

34. A method of operating a materials handling vehicle utilizing multiple detection zones comprising:

defining a first detection zone in an area proximate to the vehicle;

defining a second detection zone in an area proximate to the vehicle;

performing a first action if an unacceptable detection occurs in the first detection zone; and

performing a second action different from the first action if an unacceptable detection occurs in the second detection zone.

35. The method of claim 34, wherein the first and second detection zones are defined by at least one contactless obstacle sensor on the vehicle.

36. The method of claim 34, wherein:

said defining a first detection zone comprises defining a stop zone;

said defining a second detection zone comprises defining a first speed zone;

said performing a first action comprises implementing a stop action to stop the vehicle if the vehicle is traveling and an obstacle is detected in the stop zone; and

said performing a second action comprises implementing a speed reduction action to reduce the speed of the vehicle to a first predetermined speed if the vehicle is traveling at a speed greater than the first predetermined speed and an obstacle is detected in the first speed zone.

37. The method of claim 36, further comprising:

defining a third detection zone in an area at least partially in front of the forward traveling direction of the vehicle, the third detection zone comprising a second speed zone; and

implementing a second speed reduction action to reduce the speed of the vehicle to a second predetermined speed if the vehicle is traveling at a speed greater than the second predetermined speed and an obstacle is detected in the second speed zone.

38. The method of claim 36, further comprising preventing operation of the vehicle if an obstacle is detected within the stop zone before the vehicle begins travel.

39. The method of claim 34, further comprising:

associating each detection zone with an associated speed control zone and a corresponding maximum speed; and

limiting the vehicle speed to the predetermined maximum speed of an associated speed control zone based upon the detection of an obstacle in that speed zone.

40. The method of claim 34, further comprising modifying at least one vehicle parameter other than speed in response to detecting an obstacle in at least one detection zone.

41. The method of claim 34, wherein at least one of the detection zones comprises a steer angle correction zone, and further comprising implementing a steer angle correction if an obstacle is detected in a corresponding steer angle correction zone.

42. The method of claim 41, wherein said implementing a steer angle correction if an obstacle is detected in a corresponding steer angle correction zone further comprises selecting a direction of steer angle adjustment based upon a determination of a position of a detected obstacle.

43. The method of claim 41, wherein the at least two detection zones comprise a plurality different steer angle correction zones, and further comprising implementing a different steer angle correction amount for each steer angle correction zone.

44. The method of claim 34, further comprising remotely controlling the vehicle via a receiver at the vehicle for receiving transmissions from a corresponding remote control device, the transmissions comprising at least a first type signal designating a travel request requesting the vehicle to travel.

45. The method of claim 34, wherein said performing a first action comprises performing a first action if an obstacle is detected in the first detection zone.

46. The method of claim 45, wherein said performing a second action comprises performing a second action different from the first action if a load platform on the vehicle is not in a valid designated position.