Systems and methods of remotely controlling a materials handling vehicle

• US 8,072,309 B2
• Filed: 09/14/2007
• Issued: 12/06/2011
• Est. Priority Date: 09/14/2006
• Status: Active Grant

• Current Assignee: Crown Equipment Corporation
• Original Assignee: Crown Equipment Corporation
• Inventors: Kraimer, James V., Pollack, Jay G., Wellman, Timothy A., Jensen, Eric, Crabill, Monty, Dykema, Kurt, Duckworth, Paul, Zeilinger, Todd A.
• Primary Examiner(s): Zimmerman, Brian
• Assistant Examiner(s): Knox, Kaleria
• Application Number:
  US11/855,324
• Publication Number:
  US 20080129445A1
• Time in Patent Office: 1,544 Days
• Field of Search: 340/825, 340/5.61, 340/10.1, 340/5.52, 340/1.1, 340/4.3, 340/3.1, 340/3.7, 345/158, 180/19.1, 180/19.2, 180/19.3, 180/332, 180/333, 180/334, 341/122
• US Class Current: 340/4.3
• CPC Class Codes: B66F 9/07581 Remote controls
• CPC Class Codes: G05D 1/0016 characterised by the operator's input device input arrangements for computing systems in general G06F3/00
• 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: G08C 17/02 using a radio link
• CPC Class Codes: G08C 2201/20 Binding and programming of remote control devices
• CPC Class Codes: G08C 2201/92 Universal remote control

Abstract

A supplemental control system for a materials handling vehicle comprises a wearable control device, and a corresponding receiver on the materials handling vehicle. The wearable control device is donned by an operator interacting with the materials handling vehicle, and comprises a wireless transmitter and a travel control communicably coupled to the wireless transmitter. Actuation of the travel control causes the wireless transmitter to transmit a first type signal designating a request to advance the vehicle in a first direction. The receiver is supported by the vehicle for receiving transmissions from the wireless transmitter. A traction control of the vehicle is responsive to a receipt of the first type signal by the receiver to cause the vehicle to advance.

Claims

1. A method of associating a transmitter and a receiver in a supplemental remote control system for materials handling vehicles comprising:

initiating a power on sequence to enable a materials handling vehicle for operation, said materials handling vehicle having a receiver for receiving wirelessly transmitted travel commands;

pairing said receiver and a corresponding controller on said vehicle to a select one of a plurality of wireless remote control devices comprising;

receiving pairing mode confidence signals at said receiver of said vehicle, wherein each pairing mode confidence signal provides a transmitter identification code that uniquely identifies a corresponding one of said plurality of wireless remote control devices within range of said receiver; and

matching a known transmitter identification code associated with said select one of said plurality of wireless remote control devices with a corresponding one of the pairing mode confidence signals received by said receiver;

synchronizing said select one of said plurality of wireless remote control devices to said receiver and said controller of said vehicle such that said materials handling vehicle acknowledges remote travel commands from said select one of said plurality of wireless remote control devices by;

transmitting a first message to said select one of said plurality of wireless remote control devices that includes a receiver identification code that uniquely identifies said vehicle; and

requiring said receiver to receive a predetermined reply message in response to said first message from said select one of said plurality of wireless remote control devices; and

wherein subsequent messages wirelessly transmitted from said select one of said plurality of wireless remote control devices to said receiver identify both said transmitter identification code and said receiver identification code.

2. The method according to claim 1, wherein initiating a power on sequence to enable a materials handling vehicle for operation comprises:

requiring an operator to provide an operator identification code to said controller of said vehicle.

3. The method according to claim 1, wherein pairing said receiver and a corresponding controller on said vehicle to a select one of a plurality of wireless remote control devices further comprises displaying a list of all received pairing mode confidence signals by corresponding transmitter identification codes, said displayed transmitter identification codes being ordered by signal strength.

4. The method according to claim 3, further comprising providing said known transmitter identification code on a tag on said select one of said plurality of wireless remote control devices, wherein:

matching a known transmitter identification code associated with said select one of said plurality of wireless remote control devices with a corresponding one of the pairing mode confidence signals received by said receiver comprises locating in said list of displayed transmitter identification codes, indicia that is associated with said known transmitter identification code on said tag.

5. The method according to claim 1, wherein synchronizing said select one of said plurality of wireless remote control devices to said receiver and said controller of said vehicle comprises storing in said controller on said vehicle, said transmission identification code of the matched select one of said plurality of wireless remote control devices.

6. The method according to claim 1, further comprising:

powering off said vehicle for a period of time after successfully pairing and synchronizing said select one of said plurality of wireless remote control devices to said receiver;

starting a timer on said vehicle while said vehicle is powered down;

continuing to transmit a synchronized confidence signal by said select one of said plurality of wireless remote control devices;

powering on said vehicle;

determining if said vehicle is powered back on within a predetermined interval based upon a measurement recorded by said timer; and

if within said predetermined interval, performing;

searching for said synchronized confidence signal; and

reconfirming pairing and synchronization with said select one of said plurality of wireless remote control devices.

7. The method according to claim 6, further comprising:

requiring an operator to provide an operator identification code; and

comparing said operator identification code with a stored operator identification code recorded before powering down said vehicle, wherein;

reconfirming pairing and synchronization with said select one of said plurality of wireless remote control devices further comprises reconfirming pairing and synchronization if said operator identification code matches said stored operator identification code.

8. The method according to claim 6, further comprising:

clearing said receiver identification code stored in said select one of said plurality of wireless remote control devices when said select one of said plurality of wireless remote control devices is installed in a corresponding charging station; and

clearing said transmitter identification code stored in said controller on said vehicle after a predetermined time interval lapses after powering down said vehicle.

9. The method according to claim 6, further comprising:

entering a sleep mode by said select one of said plurality of wireless remote control devices after a first predetermined period of inactivity, wherein said select one of said plurality of wireless remote control devices continues to transmit said synchronized confidence signal;

entering a power down mode of said select one of said plurality of wireless remote control devices after a second predetermined period of inactivity in said sleep mode;

clearing said receiver identification code stored in said select one of said plurality of wireless remote control devices after a third predetermined period of inactivity in said power down mode; and

clearing said transmitter identification code stored in said controller on said vehicle after a predetermined time interval lapses after powering down said vehicle.

10. A method of associating a transmitter and a receiver in a supplemental remote control system for materials handling vehicles comprising:

initiating a power on sequence to enable a materials handling vehicle for operation, said materials handling vehicle having a receiver for receiving wirelessly transmitted travel commands;

pairing said receiver and a corresponding controller on said vehicle to a select one of a plurality of wireless remote control devices comprising;

receiving pairing mode confidence signals at said receiver of said vehicle, wherein each pairing mode confidence signal provides a transmitter identification code that uniquely identifies a corresponding one of said plurality of wireless remote control devices within range of said receiver; and

matching a known transmitter identification code associated with said select one of said plurality of wireless remote control devices with a corresponding one of the pairing mode confidence signals received by said receiver;

synchronizing said select one of said plurality of wireless remote control devices to said receiver and said controller of said vehicle such that said materials handling vehicle acknowledges remote travel commands from said select one of said plurality of wireless remote control devices;

powering off said vehicle for a period of time after successfully pairing and synchronizing said select one of said plurality of wireless remote control devices to said receiver;

starting a timer on said vehicle while said vehicle is powered down;

continuing to transmit a synchronized confidence signal by said select one of said plurality of wireless remote control devices;

powering on said vehicle;

determining if said vehicle is powered back on within a predetermined interval based upon a measurement recorded by said timer; and

if within said predetermined interval, performing;

searching for said synchronized confidence signal; and

reconfirming pairing and synchronization with said select one of said plurality of wireless remote control devices.

11. The method according to claim 10, wherein initiating a power on sequence to enable a materials handling vehicle for operation comprises:

requiring an operator to provide an operator identification code to said controller of said vehicle.

12. The method according to claim 10, wherein pairing said receiver and a corresponding controller on said vehicle to a select one of a plurality of wireless remote control devices further comprises displaying a list of all received pairing mode confidence signals by corresponding transmitter identification codes.

13. The method according to claim 12, wherein said displayed transmitter identification codes are ordered by signal strength.

14. The method according to claim 12, further comprising providing said known transmitter identification code on a tag on said select one of said plurality of wireless remote control devices, wherein:

matching a known transmitter identification code associated with said select one of said plurality of wireless remote control devices with a corresponding one of the pairing mode confidence signals received by said receiver comprises locating in said list of displayed transmitter identification codes, indicia that is associated with said known transmitter identification code on said tag.

15. The method according to claim 10, wherein synchronizing said select one of said plurality of wireless remote control devices to said receiver and said controller of said vehicle comprises storing in said controller on said vehicle, said transmission identification code of the matched select one of said plurality of wireless remote control devices.

16. The method according to claim 10, wherein synchronizing said select one of said plurality of wireless remote control devices to said receiver and said controller of said vehicle comprises transmitting a first message to said select one of said plurality of wireless remote control devices that includes a receiver identification code that uniquely identifies said vehicle, wherein subsequent messages wirelessly transmitted from said select one of said plurality of wireless remote control devices to said receiver identify both said transmitter identification code and said receiver identification code.

17. The method according to claim 10, further comprising:

requiring an operator to provide an operator identification code; and

comparing said operator identification code with a stored operator identification code recorded before powering down said vehicle, wherein;

reconfirming pairing and synchronization with said select one of said plurality of wireless remote control devices further comprises reconfirming pairing and synchronization if said operator identification code matches said stored operator identification code.

18. The method according to claim 10, further comprising:

clearing said receiver identification code stored in said select one of said plurality of wireless remote control devices when said select one of said plurality of wireless remote control devices is installed in a corresponding charging station; and

clearing said transmitter identification code stored in said controller on said vehicle after a predetermined time interval lapses after powering down said vehicle.

19. The method according to claim 10, further comprising:

entering a sleep mode by said select one of said plurality of wireless remote control devices after a first predetermined period of inactivity, wherein said select one of said plurality of wireless remote control devices continues to transmit said synchronized confidence signal;

entering a power down mode of said select one of said plurality of wireless remote control devices after a second predetermined period of inactivity in said sleep mode;

clearing said receiver identification code stored in said select one of said plurality of wireless remote control devices after a third predetermined period of inactivity in said power down mode; and

clearing said transmitter identification code stored in said controller on said vehicle after a predetermined time interval lapses after powering down said vehicle.