Multiple zone sensing for materials handling vehicles

• US 9,645,968 B2
• Filed: 12/04/2009
• Issued: 05/09/2017
• Est. Priority Date: 09/14/2006
• Status: Active Grant

• Current Assignee: Crown Equipment Corporation
• Original Assignee: Crown Equipment Corporation
• Inventors: Elston, Edwin R., Siefring, Vernon W., Jensen, Eric L.
• Primary Examiner(s): Khatib, Rami
• Application Number:
  US12/631,007
• Publication Number:
  US 20100114405A1
• Time in Patent Office: 2,713 Days
• Field of Search: 701 23, 701 28, 701 36, 701 49, 701 50, 701301, 701302
• 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: 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 three 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 stop action if the vehicle is traveling and an obstacle is detected in a first one of the detection zones comprising a stop zone;

perform a first 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 a second one of the detection zones comprising a first speed zone; and

perform a second speed reduction action to reduce the speed of the vehicle to a second predetermined speed different from the first predetermined speed if the vehicle is traveling at a speed greater than the second predetermined speed and an obstacle is detected in a third one of the detection zones comprising a second speed zone.

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

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

3. The materials handling vehicle according to claim 1, 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.

4. 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.

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

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

the at least one contactless obstacle sensor on the vehicle further defines at least one 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.

6. The materials handling vehicle according to claim 5, 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.

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

the at least one steer angle correction zone comprises 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.

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

9. The materials handling vehicle according to claim 1, wherein the second speed zone is located further from the vehicle than is the first speed zone.

10. The materials handling vehicle according to claim 9, wherein the second predetermined speed is greater than the first predetermined speed.

11. 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 speed zones, each speed zone being defined in an area at least partially in front of a forward traveling direction of the vehicle and defining a unique predetermined maximum speed greater than zero (0) miles per hour; and

a controller configured to receive information obtained from the at least one obstacle sensor to limit the vehicle speed to the predetermined maximum speed of a corresponding one of the at least two speed zones based upon the detection of an obstacle in that speed zone.

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

the controller communicates with a traction control system of the vehicle and 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.

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

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

the at least one contactless obstacle sensor on the vehicle is further operable to define at least one 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.

14. The materials handling vehicle according to claim 13, 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.

15. The materials handling vehicle according to claim 13, wherein a steer correction angle ramp rate is editable.

16. The materials handling vehicle according to claim 11, wherein the second speed zone is located further from the vehicle than is the first speed zone.

17. The materials handling vehicle according to claim 16, wherein the second predetermined speed is greater than the first predetermined speed.