EP2468678B1 - Industrial truck with a sensor for detecting the surroundings and method for operating such an industrial truck - Google Patents

Description

The invention relates to an industrial truck with a mast, on which a load carrying means with two forks is guided adjustable in height, arranged on the load supporting means sensor for detecting a spatial environment and an evaluation, which is designed to support a storage process from the detected by the sensor Data to determine a storage position, and a method for operating such a truck.

In many areas of logistics, in particular intralogistics, industrial trucks are used. In the area of general cargo transport, loading equipment in the form of pallets, lattice boxes, etc. are often used, which combine individual, smaller piece goods to load units, which then effectively and economically transported by means of industrial trucks, which are usually equipped with forks for receiving the load units , be loaded and stacked. The stacking heights in shelves reach heights of up to 10 to 13 meters, with the operator remains on the vehicle near the ground. The operator's eyes are therefore 8 to 11 meters away from the actual stacking and destacking process on the shelf, which makes the loading and unloading process more difficult, especially under bad viewing angles, poor lighting and other visual obstructions. The operation of such trucks requires a lot of experience in order to be able to perform these operations quickly, safely and effectively.

To assist the operator in this situation, the use of a video camera has become known in the field of load carrying means whose image of the operator is displayed on a monitor. The operator evaluates the video image and operates the vehicle in such a way that when stored the pallet above the shelf support collision-free deposited in the shelf and can be inserted without collision in the entry opening of the pallet during the removal of the fork.

From the publication DE 10 2004 027 446 B4 For example, a solution has been known which combines such a camera-monitor system with a height-height-selection device. The desired lifting height is preselected by the operator and automatically adjusted by the vehicle. During the lifting process, the display of the stroke height preselection is displayed and the video image of the camera monitor system is automatically displayed. With the help of the video image, the operator makes the lateral alignment of the forks. In the system described, the position of the fork tip in relation to the shelf support or to the entry opening into the range can be estimated relatively well, however, when storing a pallet, it is still difficult to properly assess the lateral distance to other pallets or side shelf posts , The required stacking depth is difficult to assess.

Another known concept provides for fully automatic storage or retrieval with inductively or mechanically positively driven high-bay stackers. Due to the forced operation, the distance of the forks or the pallet to the shelf is kept constant within small tolerances. The pallet is picked up or released laterally, transversely to the vehicle longitudinal direction, by special load-carrying means, for example swiveling push or telescopic forks. The Hubhöheneinstellung via a stroke control device, which is equipped with an actual value sensor. The lateral alignment, in the direction of travel, is carried out with the aid of expensive displacement measuring devices and, if necessary, additional markings at the storage locations and corresponding sensors on the vehicle. In one-stack direction, here transverse to the direction of travel can be worked with fixed displacement paths, since the distance of the vehicle to the shelf and the pallet length are known and constant. However, a prerequisite for such concepts is a complex system consisting of both vehicle components and stationary components. In addition, a manual stacking of pallets must be reliably prevented because otherwise can not be ensured that the pallets are positioned within the allowable tolerances. Such a fully automatic system is thus costly in purchase and operation and still not very flexible.

From the publication DE 10 2008 027 695 A1 has become known a method for storage position control with industrial trucks. The known industrial trucks have on a load carriage, below a load bearing means, a laser scanner, which detects a spatial environment, in particular below the load supporting means. From the data of the laser scanner, a storage position is determined. Subsequently, a desired position of the load supporting means is determined for approaching this storage position and finally corrects the actual position of the load bearing means accordingly.

From the publication US 2010/0091094 A1 For example, a device for measuring a volume of freight has become known. The cargo is picked up from different directions using a time-of-flight camera system.

From the publication EP 2 181 944 A1 is an industrial truck with the features of the preamble of claim 1 become known.

From the publication US 2003/044047 A1 a truck has become known in which an object recognition using two CCD cameras takes place. The image data supplied by the cameras are evaluated to detect the position of a storage bin.

From the publication DE 10 2008 020 170 A1 a method and a device for non-contact detection of the position of a vertically movable lifting device of an industrial truck has become known. At the fork is a target object having a predetermined pattern attached. A CCD camera captures an image of the target object. By evaluating the image data, the position of the lifting device can be determined.

From the publication DE 20 2006 003 211 U1 a storage system with a location marking has become known. This labeling elements are attached to the storage bins of a high-bay warehouse, which are read by a laser scanner of a truck.

The time-of-flight camera system, XP55040558, which has been researched by the European Patent Office, has become known for its different time-of-flight camera systems.

The publication US 2004/0083025 A1 describes an industrial truck with a camera system that recognizes marks M1 and M2 on pallets and shelves and displays their relative arrangement on a screen. If the positions of the markers differ in a certain way from each other, instructions for an appropriate position correction are displayed to an operator.

On this basis, it is the object of the invention to provide an industrial truck with the features of the preamble of claim 1, which supports an operator better when loading and unloading of loads, reliable and flexible and can be used for further automation, and a Method for operating such a truck.

This object is achieved by the truck with the features of claim 1. Advantageous embodiments are specified in the subsequent subclaims.

The truck according to the invention has a mast on which a load carrying means with two forks is guided adjustable in height, arranged on the load supporting means sensor for detecting a spatial environment and an evaluation unit which is adapted to support a storage operation from the data collected by the sensor one Determine storage position. The sensor has a time-of-flight camera system with a light source, a light sensor and a light entry opening, wherein at least the light entry opening is arranged in the region of a tip of one of the fork tines.

A time-of-flight camera system has a light source and a light sensor, wherein the light source transmits modulated, in particular pulsed, light which, after reflection from the objects in the image field, passes through a light entrance opening or the light entry opening onto a multiplicity of image points of the light sensor, which are like a matrix are arranged, impinges and is detected. In this case, transit time differences of the light are evaluated, so that each pixel can be assigned a value for the distance of the object. Since the optical properties of the system are known, the position of an object detected by each pixel in space can be determined in all three spatial directions. With the time-of-flight camera system, therefore, a three-dimensional "vision" of the spatial area in the direction of the camera system is possible.

The spatial image of the environment is always determined based on the location of the light sensor or the light entrance opening, so that by arranging the light entry opening in the region of a tip of one of the forks the immediate Environment of the fork tip, which is crucial for a collision-free storage and retrieval of loads, is detected particularly accurately.

A further advantage of the invention is that the image of the environment detected by the time-of-flight camera system provides a better basis for an automated evaluation of the image data than the use of a laser scanner proposed in the prior art, which additionally only provides data on individual observation planes detected.

Overall, the loading or unloading process can be optimally supported based on the data provided by the time-of-flight camera system.

In the invention, at least the light entrance opening of the time-of-flight camera system is arranged in the region of a tip of one of the fork tines. The associated light source and the light sensor can also be arranged in this area, in particular when using a camera system, are combined in the light source and light sensor to form a unit. Alternatively, the light source may be arranged at a distance from the light sensor / the light entry opening, for example in the region of the tip of the other fork tine. This makes it possible to distribute the camera system on two particularly compact units, which can be accommodated more easily in the area of the forks.

In one embodiment, the light sensor and / or the light source and / or the light entry opening is arranged in a recess of a fork tine tip. Light sensor and / or light source and / or light inlet opening can be arranged so that they do not project beyond a contour of the fork tine at any point, whereby they are reliably protected from damage. Also possible is an arrangement behind a transparent window for the light used. As a result, in particular the light sensor or the light source is additionally present Damage protected. In principle, light sensor and / or light source and / or light entrance opening not only in a recess of a fork tip, so in other words integrated into the fork tip itself, but also laterally or below the actual fork tip, where they are protected by a suitable housing or other protective Structures, for example in the form of adjacent reinforcing ribs, can be protected from damage.

In one embodiment, in each case a light sensor and / or a light source and / or a light inlet opening of a time-of-flight camera system is arranged in the region of each of the two tips of the forks, the fields of view are each directed obliquely outward from the. By using two camera systems, the environment of the two fork tips can be detected particularly reliably. This is especially true when extra-wide loads requiring a relatively large distance between the two forks are to be transported. Basically, however, the use of a single camera system is sufficient, which is arranged in the region of a tip of one of the two forks.

In the invention, the truck has a display unit connected to the evaluation unit and configured to display one or more of the following instructions to an operator in response to a current position of the load support in relation to a sensed storage position: raising or lowering load support means, Move the load support to the right or left, turn the load support around a vertical axis to the left or right, tilt the load support up or down from the horizontal, move the load support longitudinally from the rear or the back. The indicated displays can be illustrated in particular by graphic symbols which simplify the detection of the respective instruction. The instruction to Slope of the load bearing means may refer as usual to a slope of the mast with the load supporting means. The instruction to rotate the load bearing means about a vertical axis may refer to a rotation of the entire truck with the load bearing means. The instruction to move the load carrier to or from the rear may refer to movement of the entire truck with mast and load carrier or the mast with the load carrier. Required rotation of the load bearing means about a vertical axis to the left or to the right, that is viewed from above in a clockwise or counterclockwise direction, may, for example, be based on a front edge of the storage position detected by the camera system. It can be determined when the edge has a non-90 ° angle to a longitudinal direction of the load bearing means. A required inclination of the load supporting means relative to the horizontal upwards or downwards, that is a raising or lowering of the tips of the forks relative to the rear ends, in particular by means of a tilt sensor, which is arranged on the load supporting means and the measurement of an inclination of the forks relative to the Horizontal measures, be determined. The tilt sensor may be connected to the display unit for this purpose. All of the aforementioned instructions or information displayed by the display system assist an operator in collision-free loading or unloading of a load.

In one embodiment, the evaluation unit is spatially integrated into the time-of-flight camera system. This allows a particularly compact design. Retrofitting a conventional truck may also be easier.

The above object is also achieved by the method having the features of claim 5 wherein an operator is displayed in response to a current position of the load-carrying means in relation to the detected storage or retraction position one or more of the following instructions: Raise or lower the load support, move the load support to the right or left, turn the load carrier around a vertical axis to the left or right, tilt the load support up or down from the horizontal, move the load support longitudinally from the rear or back. Advantageous embodiments are specified in the subsequent subclaims.

• Erfassen einer räumlichen Umgebung des Flurförderzeugs mit dem Time-of-Flight-Kamerasystem,
• Auswerten der Signale des Time-of-Flight-Kamerasystems und Ermitteln einer Lagerungs- oder Einfahrposition,
• Bewegen des Lasttragmittels zu der ermittelten Lagerungs- oder Einfahrposition hin, und
• Aufnehmen oder Absetzen einer Last, wobei einer Bedienperson in Abhängigkeit von einer aktuellen Position des Lasttragmittels in Relation zu der erfassten Lagerungs- oder Einfahrposition eine oder mehrere der folgenden Anweisungen angezeigt werden: Lasttragmittel anheben oder der Horizontalen nach oben oder unten neigen, Lasttragmittel in Längsrichtung nach vom oder hinten bewegen.

The inventive method is used to operate an industrial truck, which has a mast on which a load carrying means with two forks is guided adjustable in height, arranged on the load supporting means sensor for detecting a spatial environment and an evaluation unit, which is designed to support a storage process to determine the data collected by the sensor, a storage position, wherein the sensor has a time-of-flight camera system with a light source, a light sensor and a light entrance opening and at least the light entrance opening is arranged in the region of a tip of one of the forks. The method comprises the following steps:

• Detecting a spatial environment of the truck with the time-of-flight camera system,
• Evaluating the signals of the time-of-flight camera system and determining a storage or retraction position,
• Moving the load supporting means towards the determined storage or retraction position, and
• Picking up or setting down a load, wherein an operator is presented with one or more of the following instructions in response to a current position of the load carrying means in relation to the detected storage or retraction position: lifting or lifting the load carrying means tilting the horizontal up or down, move the load support longitudinally to or from the rear.

For the features and advantages of the method according to the invention, reference is made to the above explanations of the corresponding features of the truck according to the invention. The storage position, which is determined based on the signals from the time-of-flight camera system, may be, for example, a parking space for a pallet on a shelf. The storage position is then characterized by a horizontally extending support for the pallet, for example comprising one or more cross members, and vertical shelf posts defining the storage position on one or both sides. A retraction position may consist in particular of the receptacles of a pallet into which the forks are moved. It has a defined and clearly defined position, which must be driven in with a fork to raise the pallet.

In one embodiment, the determination of the storage or retraction position takes place with the aid of methods of pattern recognition, whereby predefined geometric features of the storage positions or of the loads to be absorbed are detected in the data provided by the time-of-flight camera system. For example, pallets have standardized dimensions and receptacles for the forks in defined areas that give a characteristic pattern. The same applies to different shelf types whose storage positions also have characteristic features. With the aid of the pattern recognition methods, these can be recognized in the acquired data and thus the storage or retraction positions or positions of the loads themselves can be determined. The data collected by the time-of-flight camera system provides a particularly suitable basis for such pattern recognition methods.

In the invention, an operator is presented in response to a current position of the load bearing means in relation to the detected storage or retraction position one or more of the following instructions: Raise or lower load carrier, move load carrying means to the right or left, load carrying means about a vertical axis to the left or turn right, tilt the load support up or down from the horizontal, move the load support longitudinally forward or backward. By displaying the above instructions, the system supports the operator in addition to manually be performed storage and retrieval process. It is therefore an assistance system in which the driver retains control over the performance of each movement of the load carrier.

In another embodiment, the movement of the load carrying means is partially automatic, wherein an operator agrees to individual movement steps and the respective movement step is then carried out automatically without further user interaction. The consent is given, for example, by pressing an enabling button. In this embodiment, the system automatically engages in the control of the movement of the load supporting means, wherein for individual movement steps in each case a prior consent of the operator is required. This procedure can lead to a further rationalization of the stacking or unstacking operation, wherein the operator retains the possibility of intervening to correct, as far as is necessary, before each movement step.

In one embodiment of the method, the movement of the load carrying means is fully automatic, wherein after a rough positioning of the truck and / or the load supporting means by an operator moving the load supporting means to the determined storage or retraction position and the recording or discontinuation of the load by agreement of the operator without further user interaction takes place. The consent is given, for example, by pressing an enabling button. For example, the enabling button can be kept permanently depressed during the automatic movement sequences, so that the movement sequences can be interrupted at any time by releasing the button. In this embodiment, the system of the operator from further operating steps, which can lead to further rationalization.

In one embodiment, there is automatically interposed on the basis of a load detected by a load sensor and picked up by the load supporting means a deposit and a removal process distinguished, in particular, the storage of a load is automatically prevented or a warning is displayed when the presence of a load is detected in the storage space in question. In particular, it is possible to automatically recognize a pallet located on the selected storage space and to prevent a collision by displaying the warning or automatically preventing storage. An automatic differentiation between storage and retrieval processes is also useful in order to search in the evaluation of the signals of the camera system selectively either for a storage position or for a retraction position and / or the operator on a display unit only relevant to the process or information To give instructions.

In one embodiment, a marking with a predetermined geometric shape is mounted on a shelf, which is automatically detected by the evaluation and used to determine a storage position. The marking can be cuboid with defined dimensions, for example. The recognition of the marking in the data captured by the camera system can be done, for example, with methods of pattern recognition. By such a mark the recognition of a storage position can be simplified and the accuracy of the position detection can be improved.

Fig. 1

ein erfindungsgemäßes Flurförderzeug in einer schematischen Darstellung von der Seite,

Fig. 2

ein Lasttragmittel mit zwei Gabelzinken und einem Time-of-Flight-Kamerasystem, das in eine der Gabelzinken im Bereich der Spitze integriert ist,

Fig. 3

ein Lasttragmittel mit zwei Gabelzinken mit einem Time-of-Flight-Kamerasystem, wobei der Lichtsensor in einer ersten Gabelzinke und eine separate Lichtquelle in einer zweiten Gabelzinke angeordnet ist,

Fig. 4

eine Anzeigeeinheit in einer schematischen Darstellung,

Fig. 5

eine Teilansicht von einem Regal und einem Hubgerüst eines Flurförderzeugs bei einem Ausstapelvorgang in einer vereinfachten Darstellung von der Seite,

Fig. 6

eine der Figur 5 entsprechende Ansicht bei einem Einstapelvorgang,

Fig. 7

eine Draufsicht auf ein Regal und das Hubgerüst eines Flurförderzeugs von oben bei einem Ausstapelvorgang (im Bild oben) und einem Einstapelvorgang (im Bild unten),

Fig. 8

ein Blockdiagramm von Komponenten eines erfindungsgemäßen Flurförderzeugs in einer Version als Assistenzsystem,

Fig. 9

ein Blockdiagramm von Komponenten eines erfindungsgemäßen Flurförderzeugs bei einer weitergehenden Automatisierung,

Fig. 10

eine Draufsicht auf ein Regal und das Hubgerüst eines Flurförderzeugs von oben entsprechend der Figur 7 mit breiten Ladeeinheiten,

Fig. 11

eine weitere Draufsicht entsprechend der Figur 10 bei Verwendung von Markierungen an einzelnen Lagerplätzen und Verwendung eines Kamerasystems mit separater Lichtquelle.

The invention will be explained in more detail with reference to embodiments shown in FIGS. Show it:

Fig. 1

an inventive truck in a schematic representation of the side,

Fig. 2

a load carrier with two forks and a time-of-flight camera system integrated into one of the forks in the area of the tip,

Fig. 3

a load carrier with two forks with a time-of-flight camera system, wherein the light sensor is arranged in a first fork and a separate light source in a second fork,

Fig. 4

a display unit in a schematic representation,

Fig. 5

a partial view of a shelf and a mast of an industrial truck in a Unpiling in a simplified representation of the side,

Fig. 6

one of the FIG. 5 corresponding view during a stacking process,

Fig. 7

a top view of a shelf and the mast of a truck from above in a Unpile (in the picture above) and a stacking process (in the picture below),

Fig. 8

a block diagram of components of a truck according to the invention in a version as an assistance system,

Fig. 9

a block diagram of components of a truck according to the invention in a further automation,

Fig. 10

a plan view of a shelf and the mast of a truck from above according to the FIG. 7 with wide loading units,

Fig. 11

another plan view according to the FIG. 10 when using markers at individual storage locations and using a camera system with a separate light source.

FIG. 1 shows an inventive truck, shown here by way of example as a counterbalance truck, which is equipped with an assistance system for storage and retrieval of pallets, in a side view. The vehicle 1 consists of the main body 2 with front and rear axles, from the mast 3 rotatably mounted thereon, on which a load carriage 12 is guided vertically displaceable, and designated with 9 driver station module, which is mounted on the base vehicle 2 and the operator station 8 for contains the driver. Attached to the load carriage 12 are two forks 4, at least one of which near the tip of the fork has a time-of-flight camera system 5, which is arranged, including its light entry opening, laterally next to the fork tine or in a corresponding recess within the fork tip. Furthermore, an evaluation unit 6 can be seen, which can be integrated in the time-of-flight camera system or, as shown, can be separately attached to the mast 3, for example. The time-of-flight camera system 5 is electrically connected to the evaluation unit 6 in the case of a separate arrangement for supplying voltage and for exchanging signals. At the driver's seat module, a display and control unit 7 is mounted for communication with the operator, which is also electrically connected to the evaluation unit 6 or in integrated construction with the time-of-flight camera system 5. The beam path of the time-of-flight camera system 5 is indicated by the arrows 10. With 13, a sensor is designated, which determines the inclination of the forks 4. If the forks are only height-adjustable with respect to the mast 3, this sensor 13 may be attached to the mast 3, the forks are 4 tilted relative to the mast 3, the sensor 13 should be attached to the load carriage 12.

Furthermore, a measuring device 14 for determining the lifting height of the forks 4 is provided.

FIG. 2 shows a plan view of the forks 4 and the load carriage 12, the remaining components of the truck are not shown. The dashed-drawn time-of-flight camera system 5 is arranged centrally in the lower fork tine 4, for example, in its tip. Since the forks 4 and in particular their tips are exposed to high mechanical stresses in daily use, it makes sense to integrate the time-of-flight camera system 5 in the fork 4, so that it does not dominate the contour of the fork tip at any point. For this purpose, a corresponding cavity or recess can be inserted flush in this part of the fork 4. In addition to the illustrated central arrangement and a lateral arrangement in the fork tine tip 4 is possible. Furthermore, the time-of-flight camera system 5, if its size and mechanical design allows it, can also be arranged laterally on the outer edge of the fork prong 4. This assumes fewer modifications to the fork tine 4, but narrows the space for threading the fork tine tips into the entry openings of a pallet.

For the function of the time-of-flight camera system 5, it is necessary that the measurement object is illuminated by light pulses, the beam path of the light pulses is marked with 21. The beam path of the actual camera is again named 10. It can also be called the field of view of the camera system 5 or of the light sensor.

FIG. 3 again shows a top view of the forks 4 as in FIG. 2 However, the time-of-flight camera system 5 is here divided into two modules to reduce the size. In the prong shown in the picture above is the light source 23 arranged with its beam path 21, while the light sensor 22 is arranged with its beam path 10 or field of view in the lower fork 4 in the image.

FIG. 4 shows a possible embodiment of a arranged in the control room of the truck display and control unit 7. On the example touch-sensitive screen 31, the necessary for the operation of the display are shown in the case of an assistance system.

With the fields in the lower left corner 32, 33 is selected or signaled, whether it is an import or removal process A. In the illustrated case, a solid circle around the letter E indicates that it is a storage operation.

Centrally on the screen is a e.g. reversed L-shaped mark 34 symbolizing the forks 4. Around this sign are e.g. four arrows arranged to indicate whether the forks 4 are positioned correctly for safe, collision-free storage or retrieval in height and laterally. The arrow with the top pointing up here indicated by a solid line indicates that the forks 4 still need to be raised. When the correct lifting height is reached, the arrow goes out. The same applies mutatis mutandis to the downward arrow. Right and left of the L-shaped character corresponding arrows for the lateral alignment of the forks 4, transverse to the stacking direction, are shown. In the case shown, the fork tine 4 must be moved to the right.

The symbol 35 makes it clear how the vehicle and thus the forks 4 are aligned to the storage place. The upper solid line indicates the shelf or the storage place, the lower line the alignment of a line over the front edges of the fork tine tips 4. In the case shown, the vehicle is obliquely in front of the storage bin, it would have to be rotated in the counterclockwise direction, to store collision-free. The other possibilities, misalignment in the opposite direction and parallelism, are shown in dashed lines.

The symbol 36 makes it clear how the forks 4 are aligned in their longitudinal direction to the horizontal. In the illustrated case, the forks 4 are inclined backwards, so they must be rotated in the counterclockwise direction to achieve the horizontal orientation. The dashed representations are to be understood analogously.

The character 37 indicates e.g. in the form of a traffic light, whether the storage or retrieval, ie the displacement of the forks 4 in their longitudinal direction, is permitted. In the case shown, the traffic light is red, because the vehicle is still at an angle to the shelf, the forks 4 still raised, moved to the right and must be tilted counterclockwise.

By the exemplary group of characters 38 can be indicated in which direction the forks 4 must be moved in their longitudinal direction and whether a sufficient displacement is achieved. The display panel 39 indicates to the operator which shelf level has been reached in the vertical direction by raising the forks 4 in order to perform a loading or unloading operation.

FIG. 5 shows the partial side view of an unloading process shortly before threading the forks 4 in the entry openings of the loaded with a load pallet 54. This is in the second level of a shelf, which is formed from the uprights 50 and the cut shelves shown 51, 52 stacked. With the help of the height measuring device 13, the forks 4 were roughly positioned in the lifting height. The correct fork tip inclination was adjusted by means of the sensor 14 and with the assistance of the time-of-flight camera system 5, the alignment of the forks 4 is checked to the front of the shelf supports 51 and then carried out a precise positioning of the forks 4 in the vertical and in the transverse direction to the fork longitudinal direction. For this purpose, the time-of-flight camera system 5 detects the contours of the upper edge of the front support of the shelf supports 51 and the contour of the retraction openings of the pallet 54. The operator is specified on the described displays, as he has to align the forks 4, a collision-free Allow retraction.

FIG. 6 shows the partial side view of a storage operation shortly before entering the loaded with the pallet 55 forks 4 in the shelf. The height positioning takes place with the help of the time-of-flight camera system 5 and its beam path 10 and the upper edge of the front support of the shelf supports 51. For the lateral alignment transverse to the longitudinal direction of the forks 4 is now the contour of the front of the two shelf stand 50 or Side contour of a pallet already stacked on the shelf next to the shelf. Also, for aligning the pallet or the forks or the vehicle perpendicular to the shelf leading edge, as already explained, the time-of-flight camera system 5 is used.

FIG. 7 shows a shelf, consisting of the illustrated stand 50 and the shelf supports 51, the loading units 54, 55, 61 and the forks 4 in a partial section in plan view.

FIG. 8 shows a block diagram of the electronic components of the assistance system. The light sensor 22 is connected on the one hand to the separate light source 23 and on the other hand to the evaluation unit 6. The result of the evaluation is communicated to the display and operating unit 7. This shows according to the operator FIG. 4 on how to use the truck. Furthermore, the Hubhöhenmesseinrichtung 13 and the tilt sensor 14 are connected to the display and control unit 7. The actuation of the button 76 switches the display of Results of the image analysis of the time-of-flight camera system 5 on the screen of the display and control unit 7 a.

FIG. 9 shows a block diagram in the event that the assistance system described is extended so that a partially or fully automated storage or retrieval can be realized. In this case, the display and operation unit 7 is as in FIG. 8 connected to the evaluation unit 6. In addition, a wireless connection, for example, a radio link 71 to a control system 70 and a connection to a consent button 72. The Hubhöhenmesseinrichtung 13 and the tilt sensor 14 are connected to an interface unit 73 to the signal network 74, for example, the CAN bus, the truck is connected with its control device 75. About this network is also the connection to the display and control unit. 7

For different stages of development, which will be explained in more detail later, are still connected: the vehicle-side part 92 of a positioning system, a load detection sensor 93 and a device for loading units identification, e.g. Bar code reader 90, for reading a bar code 91 mounted on the loading unit.

FIG. 10 shows a shelf consisting of the illustrated stand 50 and the shelf supports 51, the particularly wide loading units 84, 85 and the forks 4 with time-of-flight camera systems 5 with integrated light source in a partial section in plan view.

FIG. 11 shows a shelf, consisting of the illustrated stand 50 and the shelf supports 51, the particularly wide loading units 84, 85, the forks 4 with a light sensor 22 and a separate light source 23 in a partial section in plan view. Furthermore, rectangular markings 80, which are shown in dashed lines, attached to the shelf supports 51 also partially shown in dashed lines so that they are always assigned to the respective pallet space in the same way.

• Der Fahrer wählt über die Taste 33 der Anzeige- und Bedieneinheit 7 die Funktion Auslagerung und positioniert das Flurförderzeug so vor dem Regal, dass die Gabelzinken 4 nur noch geringfügig seitlich bewegt werden müssen, wenn sie auf die richtige Hubhöhe gehoben worden sind. Sodann richtet er mit Hilfe der Sensorik 14 und der Anzeige 36 auf der Anzeige- und Bedieneinheit 7 die Gabelzinken 4 horizontal aus. Dann erfolgt mit Hilfe der Hubhöhenmesseinrichtung 13 und der Anzeige 39 das Anheben der horizontalen Gabelzinken 4 auf die richtige Regalebene. Jetzt können mit Hilfe einer Taste 76 die Anzeigen 34 und 35 aktiviert werden.

The function of the industrial truck according to the invention and the method according to the invention will be explained below on the basis of three examples which have different degrees of automation. In a first embodiment, the system of time-of-light camera system 5, evaluation unit 6 and display and operating unit is used as an assistance system. The driver of the truck is supported in the operation of the vehicle during storage and retrieval by displaying on the display and control unit 7. A paging operation can be performed as follows:

• The driver selects via the button 33 of the display and control unit 7, the function of outsourcing and positioned the truck in front of the shelf that the forks 4 only have to be moved laterally slightly when they have been raised to the correct lifting height. He then aligns the forks 4 horizontally with the aid of the sensor system 14 and the display 36 on the display and operating unit 7. Then with the help of the Hubhöhenmesseinrichtung 13 and the display 39, the lifting of the horizontal forks 4 on the correct shelf level. Now, with the help of a button 76, the displays 34 and 35 can be activated.

The front of the shelf supports 51 and the pallet of the loading unit 54 are illuminated by the light source of the time-of-flight camera system 5 and the separate light source 23, the reflected light pulses are detected by the light sensor 22 and forwarded to the evaluation unit 6. Here, a comparison of the signals with known patterns of shelf supports and pallets located thereon and in particular their entry openings. The display 37 shows, for example, the color red, ie the forks 4 must not yet be moved in the direction of the fork tines because, after evaluating the signals of the time-of-flight camera system 5, they are moved in accordance with FIG FIG. 4 still have to be moved to the right and up. Furthermore, it is determined with the help of the light reflections of the front shelf level, whether the forks 4 are perpendicular to the shelf support in their longitudinal direction. This is according to display 35 in FIG. 4 not the case, the vehicle is at an angle to the shelf support and must be aligned accordingly by driving maneuver of the operator. As soon as sufficient perpendicularity is given, the display 35 shows, for example, two parallel lines. The correction of the vertical position is made by utilizing the lift / lower function of the vehicle, for the correction in the transverse direction are known side thrusters that can move the forks 4 relative to the vehicle or mast or load carriage 12 in the transverse direction. Are the forks 4 correctly positioned in front of the entry openings of the pallet of the loading unit 54, only the fork 4, but no arrow is displayed in display 34 and the display 37 shows in the lower circle the color green, ie the forks 4 can now in their longitudinal direction by moving the mast and / or method of the vehicle to be moved in the fork longitudinal direction. When the forks 4 are fully inserted into the openings of the pallet of the loading unit 54, the operator lifts the forks 4 and thus also the loading unit 54 and stacks them.

In a further advantageous embodiment of the system, the distance information of the time-of-flight camera system 5 is used to the shelf supports 51. When inserting the forks 4 into the entry openings of the pallet of the loading unit 54, the time-of-flight camera system determines the distance to the front shelf support. With proper storage of the loading unit 54, this results in the required travel of the forks 4 in their longitudinal direction, so that the fork back comes to rest on the loading unit and the loading unit thus properly positioned on the forks 4. The displacement of the forks 4 results depending on the vehicle type relative to the base vehicle. For the determination of these ways solutions are known and are therefore not described in detail. The operator is indicated with the display 38 by the arrow pointing to the left, that the forks 4 must be moved in the direction of the shelf. If the forks 4 have passed through the displacement path resulting from the loading units and shelf dimensions, the arrow in display 38 goes out and thus indicates to the operator a sufficient displacement.

A storage operation can be carried out as follows: The driver selects via the key 32 of the display and control unit 7, the function storage and positioned the truck in front of the shelf that loaded with the loading unit 55 forks 4 must be moved only slightly laterally, if they have been raised to the correct lifting height. He then aligns the forks 4 horizontally with the aid of the sensor system 14 and the display 36 on the display and operating unit 7. Then with the help of the Hubhöhenmesseinrichtung 13 and the display 39, the lifting of the horizontal forks 4 on the correct shelf level. Now, with the help of a button 76, the displays 34 and 35 can be activated.

The front of the shelf supports 51 and the side of the empty pallet storage space located, vertical shelf stand 50 and the adjacent, standing on the shelf loading unit 61 after FIG. 7 are illuminated by the light source of the time-of-flight camera system 5 or the separate light source 23, the reflected light pulses are detected by the light sensor 22 of the time-of-flight camera system 5 and forwarded to the evaluation unit 6. Here is a comparison of the signals with known patterns of shelf supports and pallets located on it or side shelf stands. The display 37 shows, for example, the color red, ie the forks may not yet be moved in the fork tine longitudinal direction, because according to evaluation of the signals of the time-of-flight camera system 5 according to FIG. 4 still have to be moved to the right and up. Furthermore, it is determined with the help of the light reflections of the front shelf level, whether the forks 4 are perpendicular to the shelf support in their longitudinal direction. This is according to display 35 in FIG. 4 not the case, the vehicle is at an angle to the shelf support and must be aligned accordingly by driving maneuver of the operator. Once a sufficient squareness is given, the display 35 shows, for example, two parallel lines. Are the forks 4, based on the vertical direction, correctly to the shelf support 51 and the side shelf stanchions or neighboring loading units, based on the transverse direction, positioned in display 34, only the fork tine 4, but no arrow is displayed and the display 37 shows in the lower circle the color green, ie the loading unit can now be moved in its longitudinal direction by moving the mast and / or method of the vehicle in the fork longitudinal direction. When the loading unit 55 is sufficiently far inserted into the shelf, the operator lowers the forks 4 and thus sets the loading unit 54 on the shelf supports 51 from.

Also in this storage process, the distance measurement described above can be used to indicate to the operator that the loading unit is sufficiently deep stacked. In a further advantageous embodiment of the invention, when the fork tines 4 are not permitted to be retracted into the entry openings of the pallet or if the loading unit is not allowed to be stacked, both indicated by the red display 37, the forks 4 are automatically prevented in their longitudinal direction by moving the vehicle and / or advancing the mast can be moved.

In a more extensive automation, the described processes can be partially automatic. The operator positions the empty, or loaded with a loading unit forks 4 roughly in front of a shelf, raises the forks. 4 up to the lowermost shelf support, for example, and positions the vehicle with the aid of driving and steering maneuvers and the display 35 perpendicular to the shelf level as soon as the time-of-flight camera system 5 has detected the front of the shelf supports 51 and the display 35 with the button 76 was activated. The bottom shelf level is particularly suitable for orientation because it can be easily seen by the driver.

Then, the operator raises the forks 4 and the loading unit by means of the Hubhöhen sensor 13, which is connected via the interface unit 73 and the CAN bus 74 with the vehicle control device 75 and the display and control unit 7, and the display 39 to the approximately correct Lifting height and actuates the enabling button 72. Now receives the vehicle control device 75 via the vehicle signal network 74 of the display and control unit 7, the command "forks horizontal". With the help of the tilt sensor 14, which is connected via the interface unit 73 and the CAN bus 74 to the vehicle control device 75, the forks 4 are automatically aligned horizontally by the vehicle control device 75 and the vehicle functions. Then, always with the previous operation of the approval button 72 by the operator commands from the display and control unit 7, such as "lifting", "lowering", "side thrust left" and "side thrust right" over the signal network 74 to the vehicle control device 75, until the forks 4 are aligned to the entry openings and the shelf support or the loading unit for shelf support and the lateral boundaries (rack stand or neighboring range) automatically, using the signals of the evaluation unit 6. Now the operator is indicated via the displays 37 and 38 as he has to move the forks 4 and the loading unit 55 in the longitudinal direction of the fork, to ensure a proper recording or settling of the loading unit.

In a further advantageous embodiment of the partial automation, the displacement of the fork tines 4 or of the loading unit in the fork longitudinal direction is also handled automatically by commands of the display and operating unit 7 to the vehicle control device 75. For this purpose, the functions mast forward feed or vehicle travel forward in conjunction with the feed and / or travel measurement and the distance measurement via the time-of-flight camera system 5 are used. This description applies analogously to the loading and unloading of loading units.

In a further advantageous embodiment of the invention, the stacking of the charging unit is prevented when the time-of-flight camera system 5 detects the contour of a pallet, although the storage space for the intended storage (button E 32 actuated) of a loading unit must be free. In addition, the signal of the load detection sensor 93, which detects the load unit located on the forks 4, with the signal of the time-of-flight camera system 5, that there is already a pallet in the designated storage space, linked and prevented so that a Loading unit is stacked on an occupied storage space.

Also possible is a fully automatic storage and retrieval. In this case, in addition to the explained partial automation, a wireless connection, in particular a radio link 71 between the display and control unit 7 on the vehicle and a stationary forklift control system 70 is used.

This control system 70 receives from a warehouse management system 77 the command, a particular loading unit (eg 54 or 55) on a certain shelf space or outsource. The control system selects a suitable industrial truck and passes this to the corresponding infeed or removal order via the wireless radio link 71 to the on-board display and operating unit 7. There, this order is displayed to the operator. The server will pick up at one Storage order, the loading unit at the specified, so-called source from, or moves in a removal order with unloaded forks 4 to the specified pickup location. He positioned the vehicle in front of the corresponding shelf and presses the consent button 72. Then, the display and control unit 7 generates the command "lifting" until the unit 7 known height of the first shelf support is reached. Now, the automatic interrogation of the signal of the time-of-flight camera system 5 for vertical alignment of the vehicle takes place in front of the shelf. For this purpose, the driver is shown the current actual orientation with the aid of the display 35. After alignment by means of driving and steering maneuvers by the operator, the display 35 shows, for example, two parallel lines and the operator actuates the consent key 72. Now generates the display and control unit 7 the command "lifting" until the unit 7 off the input or Auslagerauftrag known height of the respective shelf support using the signals of the height measuring device 13 is reached. Now, as described above for partial automation, the correction in vertical and transverse direction with the aid of the signals of the time-of-flight camera system 5 and the automatic insertion of the forks or the charging unit.

In the case of very wide loading units 84, 85, the horizontal opening angle of the beam path of a time-of-flight camera system 5 may not be sufficient to simultaneously detect the lateral boundaries of the intended storage space on the shelf when storing a loading unit 85 (see FIG Fig. 10 below). In this case, a time-of-flight camera system 5 can be provided in each fork tip 4, wherein for the lateral orientation of the loading unit 85 located in the left fork prong 4, on the left lateral boundary (here the shelf stand 50) and the Camera system 5 located in the right fork prong 4 focuses on the right boundary (here the left corner of the loading unit 84). The same applies to the case of outsourcing ( Fig. 10 above). Here, the respective time-of-flight camera system 5 focuses on the right or left entry opening of the pallet of a loading unit 84 to be outsourced. For the alignment in height, the time-of-flight camera systems 5 in both cases use the upper edge of the front the two shelf supports 51.

Alternatively, according to Fig. 11 each storage space on the shelf with one of the time-of-flight camera system 5 recognizable, three-dimensional, eg cuboid marking 80 are provided, since the truck facing side of the cuboid has a smaller distance from the time-of-flight camera system 5 serves as the front of the front of the two shelf supports 51, for lateral positioning in the transverse direction. In this embodiment, as in the Figures 3 and 11 shown again to be worked with a single light sensor 22 and a separate light source 23.

In a further advantageous embodiment, the truck can be additionally equipped with one of the known positioning system 92, so that the operator is assisted in the search for the intended storage or retrieval space. The operator is thereby e.g. by appropriate displays, as they are known from the field of passenger car navigation systems, informed on the screen of the display and control unit 7, in which direction he has to steer the truck to the storage or retrieval, the display and control unit 7 is communicated from the warehouse management system 70 via the wireless communication 71.

By incorporating means for identifying a forklift 4 located on the loading unit 55 and 85, a further advantageous embodiment can be achieved. For this purpose, for example, a barcode scanner 90 is to be integrated within the load carriage 12 in such a way that, for example, barcode stickers 91 which are mounted on the loading unit 54, 55, 84, 85 in the detection area of the barcode reader are read automatically when retracting the forks 4 in the loading unit 54, 55, 84, 85. The reading result is given by the identification unit 90 to the display and operating unit 7, where the identified loading unit with the respective place where the truck and thus the loading unit is located, is linked.

With the aid of an additional load detection sensor 93, which detects whether or not a loading unit is located on the forks, it is now possible, if necessary with the aid of the knowledge of the respective current vehicle functions, e.g. Lifting, lowering, driving forward, reversing, etc., be inferred by logically linking the corresponding signals in the display and control unit 7 that e.g. a certain, identified loading unit was picked up or deposited at a certain location at a certain height, that is to say it was stored or retrieved. This information can then be communicated from the display and control unit 7 via the wireless communication 71 and the control system 70 to the warehouse management system 77 where it is e.g. for updating and verifying the storage allocation stored in system 77.

Furthermore, it is possible with the invention described in combination with a known operating data acquisition system for industrial trucks, possible incorrect operations in storage and retrieval operations the respective operator who must identify himself in this system before operation, and thus achieve at least one "educational effect".

• Erhöhung der Produktivität des Staplereinsatzes durch Verkürzung der Zeiten für die Ein- und Auslagerung von Ladeeinheiten, insbesondere bei größerer Hubhöhe,
• Unterstützung von insbesondere ungeübten Bedienern,
• Verbesserte Ergonomie, da das Verfolgen des Ein- und Auslagervorgangs in größeren Höhen eine sehr unbequeme oder ungesunde Körperhaltung des Bedieners voraussetzt,
• Verbesserte Sicherheit für Personen, Lagereinrichtung und Ladeeinheiten,
• Möglichkeit der automatischen Bildauswertung mit Hilfe des Time-of-Flight-Kamerasystems zur Nutzung für teilautomatisierte Ein- und Ausstapelvorgänge,
• Unterschiedliche Ausbaustufen von Assistenzsystemen über Teilautomatisierung bis Vollautomatisierung,
• Vermeidung von Fehlbedienungen möglich, inkl. Zuordnung zu einzelnen Bedienern,
• Integration einer automatischen Ladeeinheiten-Identifikation möglich,
• Integration eines Ortungssystems möglich,
• Ausbau bis zu einem Ladeeinheiten-Verfolgungssystem inkl. der Möglichkeit zur Verifizierung der Lagerbestandslisten,
• Flexible Reaktion auf nicht ordnungsgemäß eingestapelte Ladeeinheiten oder sich ändernde Lagerraster, usw.

In summary, the following advantages can be achieved with the invention:

• Increasing the productivity of the truck use by shortening the times for the loading and unloading of loading units, especially for larger lifting heights,
• Support for inexperienced operators
• Improved ergonomics, as tracking the loading and unloading process at higher altitudes requires a very uncomfortable or unhealthy posture of the operator,
• Improved safety for persons, storage facilities and loading units,
• Possibility of automatic image analysis using the time-of-flight camera system for use in semi-automated stacking and unstacking operations,
• Different expansion stages of assistance systems via partial automation to full automation,
• Avoidance of incorrect operation possible, incl. Assignment to individual operators,
• Integration of an automatic loading unit identification possible,
• Integration of a location system possible,
• Upgrading to a loading unit tracking system, including the ability to verify stock lists,
• Flexible response to improperly stacked load units or changing storage grid, etc.

Claims (12)

1. An industrial truck with a lifting frame (3), on which a load-bearing means with two fork arms (4) is guided in a height-adjustable manner, a sensor arranged on the load-bearing means for capturing the spatial surroundings and an evaluation unit (6), which is designed to determine a storage position from the data captured by the sensor to support a warehousing process, characterized in that the sensor comprises a time-of-flight camera system (5) with a light source (23), a light sensor (22), which comprises a plurality of image points arranged in a matrix-like manner, and a light inlet opening, wherein at least the light inlet opening is arranged in the area of a tip of one of the fork arms (4) and the industrial truck has a display unit (7), which is connected with the evaluation unit (6) and is designed to display the following instructions to an operator depending on a current position of the load-bearing means in relation to a captured storage position: rotate the load-bearing means to the left or right around a vertical axis, wherein the evaluation unit (6) is designed to determine based on a front edge of the storage position captured by the time-of-flight camera system (5) whether a longitudinal direction of the load-bearing means has an angle with respect to the edge deviating by 90°.
2. The industrial truck according to claim 1, characterized in that the light sensor (22) and/or the light source (23) and/or the light inlet opening is arranged in a recess of the form arm tip.
3. The industrial truck according to claim 1 or 2, characterized in that respectively one light sensor (22) and/or a light source (23) and/or a light inlet opening of a time-of-flight camera system (5) is arranged in the area of each of the two tips of the fork arms (4), the fields of vision of which are directed diagonally forwards and outwards.
4. The industrial truck according to claim 1 to 3, characterized in that the display unit (7) for displaying one or more of the following instructions to an operator is designed depending on the current position of the load-bearing means in relation to a captured storage position: lift or lower the load-bearing means, move the load-bearing means right or left, tilt the load-bearing means up or down with respect to the horizontal line, move the load-bearing means forward or backward in the longitudinal direction.
5. The industrial truck according to claim 1 to 4, characterized in that the evaluation unit (6) is integrated spatially in the time-of-flight system (5).
6. A method for operating an industrial truck, which has a lifting frame (3), on which a load-bearing means with two fork arms (4) is guided in a height-adjustable manner, a sensor arranged on the load-bearing means for capturing the spatial surroundings and an evaluation unit (6), which is designed to determine a storage position from the data captured by the sensor to support a warehousing process, wherein the sensor comprises a time-of-flight system (5) with a light source (23), a light sensor (22), which comprises a plurality of image points arranged in a matrix-like manner, and a light inlet opening and at least the light inlet opening is arranged in the area of a tip of one of the fork arms (4), with the following steps:

   • capturing of a spatial surroundings of the industrial truck with the time-of-flight camera system (5),

   • evaluation of the signals of the time-of-flight camera system (5) and determining of a storage and entry position,

   • movement of the load-bearing means towards the determined storage or entry position, and

   • receiving or putting down of a load, wherein

   • the following instructions are displayed to an operator depending on a current position of the load-bearing means in relation to the captured storage or entry position: rotate the load-bearing means to the left or right around a vertical axis, wherein the evaluation unit (6) is designed to determine based on a front edge of the storage position captured by the time-of-flight camera system (5) whether a longitudinal direction of the load-bearing means has an angle with respect to the edge deviating by 90°.
7. The method according to claim 6, characterized in that the determining of the storage or entry position takes place with the help of methods of pattern recognition, wherein predefined geometric characteristics of the storage positions or of the loads to be received are detected in the data made available by the time-of-flight system (5).
8. The method according to claim 6 or 7, characterized in that one or more of the following instructions is displayed to the operator depending on a current position of the load-bearing means in relation to a captured storage or entry position: lift or lower the load-bearing means, move the load-bearing means left or right, tilt the load-bearing means up or down with respect to the horizontal line, move the load-bearing means forward or backward in the longitudinal direction.
9. The method according to one of claims 6 to 8, characterized in that the moving of the load-bearing means takes place semi-automatically, wherein an operator approves individual movement steps and the respective movement step is then executed automatically without further user interaction.
10. The method according to one of claims 6 to 8, characterized in that the moving of the load-bearing means takes place fully automatically, wherein, after a rough positioning of the industrial truck and/or the load-bearing means by an operator, the moving of the load-bearing means towards the determined storage or entry position and receiving or putting down of the load takes place through approval of the operator without further user interaction.
11. The method according to one of claims 6 to 10, characterized in that an automatic differentiation is made between a warehousing and a retrieval process based on a load determined with a load sensor and received by the load-bearing means, wherein in particular the warehousing of a load is automatically prevented or a warning is displayed when the presence of a load is detected at the concerned storage area.
12. The method according to one of claims 6 to 11, characterized in that a marking (80) with a specified geometric shape is applied to a shelf, which is automatically detected by the evaluation unit and used to determine a storage position.

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